RISK ASSESSMENT

1.0 Hazard
In practical terms, hazard identification is a thorough look at the workplace and processes to
identify those things, situations, processes that may cause harm, particularly to the working
force and nearby population. After identification of the potential hazards, one has to evaluate
it potential to cause harm and then decide what type of control measures shall be taken to
control it from the happening. Hazard identification is very important tool as it is integral
part of a good occupational health and safety management plan. The aim of the hazard
identification process is to reduce level of risk by taking precautions or initiating control
during project execution. The various hazard analysis techniques that may be applied are
Hazard and Operability (HAZOP) studies, Fault – Tree Analysis (FTA), event –tree analysis
and failure and effects mode analysis.

1.1 Hazard Identification & Risk Assessment (HIRA)

The purpose of a Hazard Identification and Risk Assessment (HIRA) is to understand what
risks or threats to public safety, property or the environment exist

Figure 7.1 : Hazard Identification & Risk Assessment (HIRA) process

Hazard Identification and Risk Assessment (HIRA) Process,
 Identification of hazards
 Analyze or evaluate the risk associated with the hazards
 Determine appropriate ways to eliminate or control the hazards
 Evaluate the likelihood of an injury or illness occurring, and its severity
 Review of all available health and safety information about the hazard including MSDS,
manufacturer’s literature, information from organizations and results of testing
 Identify actions necessary to eliminate or control the risk
 Monitoring to confirm the risk is controlled
  Keep any documentation or records that may be necessary. Documentation may include
detailing the process used to assess the risk, outlining any evaluations, or detailing how
conclusions were made.

1.2 Identification Hazard

Details of major anticipated risks from the Hazards is given in Table 7.1
Table 7.1: Hazards of the proposed plant
Sr. Name Description Severity Hazard
No.
1. Transportations of raw Molasses Major Exposure
material Yeast, urea Minor Exposure &
inhalation
Sulphuric Acid, Di Major Exposure &
ammonium Phosphate, inhalation
Anti- foam reagent,
2. Storage of Molasses Caustic soda
Molasses, RS/ ENA/ Major Explosion, Fire
Products and Technical Alcohol,
byproducts fusel oil
3. Manufacturing Fermentation Major Fire
process Distillation Unit Major Heat & fire
Power Plant Major Heat fire &
electrocution
4. Utilities D.G set, Boiler, Turbine Major Heat, fire &
electrocution
5. Other accidents Leakages from the Major Exposure & fire
vessels,
Catastrophic
rupture of
pressure vessels
and Storage Tanks

1.3 Risk Assessment

Risk analysis deals with the identification and quantification of risks, the plant equivalent
and personnel are exposed to, due to accidents resulting from the hazards present in the
factory. Risk classification table is given in Table 7.2.

Table 7.2: Risk classification and score table

1.4 Potential risk and mitigation measures for during construction phase
Risk impact and mitigation measures during construction phase are describes in Table 7.3
Table 7.3: Risk Impact and rating matrix during construction phase
Activity Associated Health impact Risk Proposed mitigation
Hazards rating and control measures
Site Leveling Vehicular Physical injury, M  Providing PPEs to
movement, and organ workers
Insect / snake damage  Appointing the qualified
bite persons for the
particular job.
 Speed limit control
 Providing Training
Loading and Accidents Physical Injury M  Providing PPEs to
Unloading of workers
material  Training to workers
Excavation  Falling Property Loss M  Work Permit System
objects or Physical injury will be followed.
objects near an  Excavated material
excavation will be stacked safely.
 Slips, trips,  Area will be
and falls barricaded
 Training to workers
 PPEs will be provided
Construction  Structure Physical Injury H  Work Permit System
may fall down Physically will be followed.
 Workers may handicapped  Height work permit
fall down Property will be issued to the
from the Loss person.
height.  Safety belt will be
provided to workers
 Training to workers
Cutting and Fire or explosion Physical Injury H  Standards Work
Welding Burn Injury  Procedure
Electric Property loss  Training will be
shock from provided
electrical  Proper PPEs will be
welding  Provided.
 Regular monitoring of
electrical equipment’s
to avoid loose
connection
 Area will be
barricaded
Installation Structure Property loss M  Only authorized
of may collapse Physical Injury person will operate
Machineries. the machine
 Appropriate
platform will be
designed as per the
 load bearing
calculation.

1.5 Potential risk and mitigation measures during operation phase

1.5.1 Boiler Operation
The potential risk and its mitigation measures for Boiler operation is given in Table 7.4.
Table 7.4: Risk Impact and rating matrix for Boiler operation
Activity Associated Health impact Risk Proposed mitigation
Hazards rating and control measures
Working near High noise Noise induced M Required PPEs need to
Boiler hearing loss be used PPEs
Boiler Mechanical Physical M  Regular monitoring
maintenance hazard injury for checking leakages
 Individual vigilance
and proper training to
worker for proper
handling
 Provision of First aid
box
High Pressure Explosion Risk of H  Required PPEs
Steam severe  Good housekeeping
injury, damage  Regular monitoring of
to equipment the storage facility
 Flammable
chemicals stored away
from the source of
ignition
 Firefighting facility
 Provision of First aid
Box
 Incomplete Asphyxiation Possible H  Online CO monitors
Combustion from carbon fatality  Regular checking of
monoxide workplace
 Individual alertness
and precaution
Maintenance Slips, Trips Physical M  PPEs Individual
work and Falls injury alertness and
precaution
Electrical Electricity Electric H  Regular checking
maintenance shock, and maintenance
work Possible of electrical units PPEs
burns  Provision of First aid
box
Maintenance Burn injury Severe M  PPES will be provided.
of burner Physical  Work will be carried out
injury or under proper
burn  supervision.
 Follow of SOPs.
 Individual alertness
and precaution is
important
 Provision of First aid box

1.6 Risk during D.G. set operation

Table 7.5:
Risk Impact and rating matrix for D.G. set operation
Activity Associated Health impact Risk Proposed mitigation
Hazards rating and control measures
Working High noise Noise induced M  Use of PPEs
near DG hearing loss  Acoustic enclosure
Maintenance Fire Burns, H  Restricted Entry
Serious injury  Use of flame proof
fittings
 Use of PPEs
 HSD Storage Leakage / Risk of severe H  Storage will be away
Fire physical from ignition source
injury and  Regular monitoring to
burn check the leakages and
spillages
 Firefighting facility
will be provided
 PPEs will be provided
 First aid box
DG set Mechanical Physical injury M  PPEs
maintenance Hazard  Leakage and heat
in the joint will be
checked before
maintenance
 First aid box at
approachable place

1.7 Hazard & associated Risk of storage and handling of raw material
Impact matric for risk associated with storage and handling of material is given in Table 7.6.
Grain and alcohol storage Tanks details are given in Table 7.8. Material safety data sheets
for Chemicals are enclosed as Annexures.
Table 7.6: Impact matrix of Storage and handling of raw material
Activity Associated Health impact Risk Proposed mitigation
Hazards rating and control measures
Storage, Exposure, Physical Injury, H  Provision of Eye wash
handling, leakage, burn, Eye  Inspection and
loading & Fire, irritation and regular monitoring of
Unloading of Explosion respiratory storage area.
material problem  Training to Workers
for proper handling
PPEs will be provided
as Nose mask, Hand
gloves.
  Proper system for
loading operation to
prevents spillage
 Provision of level
indicators for storage
Tanks
 Spill kit for Acid and
other chemicals
 Proper ventilation
 First Aid boxes
Transportation Fire, accident, Burns, Serious H  Fire fighting
leakage injury  Training to driver
 MSDS
 Trem Card
 First Aid Box

1.8 Hazard & associated Risk of Molasses storage tank

Molasses can ferment if excessive moisture contamination is allowed. Fermentation can
yield carbon dioxide with possible traces of ethanol or volatile fatty acids (e.g. acetic,
propionic, lactic, or butyric) and if exposed to a spark or flame may result in an explosion.
Fermentation may also occur in dilute surface layers formed by condensation from the
headspace above the liquid.
Table 7.7: Impact matrix of storage of molasses
Activity Associated Health impact Risk Proposed mitigation
Hazards rating and control measures
Storage and Explosion  May cause slight H  Proper ventilation
Handling irritation shall be provided
 May cause irritation  Inspection and
regular monitoring of
storage area
 Training to Workers
for proper handling
  PPEs will be provided
as Nose mask, Hand
gloves.
 Provision of level
indicators for storage
Tanks.
 If causes eye irritation
wash area with soap,
flood eye with water
and water

1.9 Risk associated with alcohol storage and its mitigation measures
Material Safety Data Sheet (MSDS) for ethyl alcohol is enclosed as Annexure. Impact matric of
risk associated with storage and transportation of alcohol along with control and mitigation
measures are given in Table 7.9.
Table 7.9: Impact matric of risk associated Alcohol storage
Activity Associated Health impact Risk Proposed mitigation
Hazards rating and control measures
Storage Exposure,  Exposure to over H Storage
of Alcohol inhalation, 1000 ppm may  Storage will be
ingestion & cause headache, away from process
Fire drowsiness and area with well-
lassitude, loss of ventilation.
appetite, and  Avoid all possible
inability to sources of ignition like
concentrate. Throat spark or flame.
Irritation  Use spark/flame
 Ingestion causes proof hand tools
depression of  Electrical wiring will
central nervous be flame proof type
system, nausea,  Based on the
vomiting, and leakage quantity,
diarrhea wiped out with or
  Liquid or vapor dilute by spraying the
may cause eye and water to suppress the
skin irritation vapors
 Burn injury Control measures in
case of over exposure

 If victim is
conscious and able
to swallow, then give
water or milk to drink
to dilute the contents
in the stomach
 Look out for
medical help

Skin or Eye exposure

 Immediately flush
affected area with plenty
of water. Eyes should be
flushed for at least 15
Minutes with water.
 PPEs will be provided to
avoid exposure.

1.10 Risk associated with work area of distillation

Table 7.10: Impact matric of risk associated distillation area
Sr. Activity Associated Health Risk Proposed Control and
No. Hazards impact rating mitigation measures
1. Working near Heat & Fire Physical H  PPEs
Distillation injury &  Firefighting facility
column burning  First aid box
 Periodic checking of all
parts

1.11 Safety Measures Recommendation

1.11.1 Storage and material handling area
 Proper ventilation shall be provided
 Area will be marked as “No smoking Zone”
 Use of proper PPEs
 Pressure relief valves shall be provided
 Provision of Safety valves and rupture disk
 Provision of fire hydrant system along with other portable fire extinguishers
 Adequate distance between the storage Tanks
 Provision of dyke wall to the Tanks
 Proper earthing to the Tanks

1.11.2 Reactor Safety

 Provision will be made for temperature & pressure indicators
 Heating & cooling Jacket will be provided to maintain the temperature
 Pressure switch with hooter shall be provided
 Pressure safety valve will be provided
 Double earthing shall be provided

1.11.3 DG Sets
 Acoustic enclosures to be provided
 Entry near the unit shall be restricted
 Qualified and highly trained engineers shall be appointed

1.11.4 Boiler
 Work permit system will be evolved and will be followed during maintenance work
 Proper ventilation shall be maintained
 Entry shall be allowed only after proper checking of gases, if any
 Worker should be trained properly
 Working should be under supervision of qualified and trained personnel

1.11.5 Storage and Handling of Alcohol

 Keeping away from oxidizers, heat and flames.
 Avoidance of plastics, rubber and coatings in the storage area.
  Cool, dry, and ventilated storage and closed containers.
 Leakage should be washed out and diluted.
 Regular monitoring and maintenance to avoid leakages.
 If major leakage in tanks can be mitigated by transferring the material to other tank.
 Transfer the material to other tank.
 Grounding of the container and transferring of equipment to eliminate static electric sparks.
In case of any emergency following measures would be taken:
 First Aid Measures
 Use of extinguishing media surrounding the fire as water, dry chemicals (BC or ABC powder)
sand, dolomite, etc
 Foam system for firefighting will be provided to control fire from the alcohol storage tank.
The foam thus produced will suppress fire by separating the fuel from the air (oxygen), and
hence avoiding the fire and explosion to occur in the tank. Foam would blanket the fuel surface
smothering the fire. The fuel will also be cooled by the water content of the foam. The foam
blanket suppresses the release of flammable vapors that can mix with the air.
 Special Fire Fighting Procedures; Keeping the fire upwind. Shutting down of all possible
sources of ignition, keeping of run-off water out of sewers and water sources. Avoidance of
water in straight hose stream which will scatter and spread fire. Use of spray or fog nozzles
will be promoted, cool containers will be exposed to flames with water from the side until
well after the fire is out.

1.11.6 Molasses storage

 Store in good quality ventilated and leak-proof tanks (mild steel, stainless steel,
polyethylene, PVC) at ambient temperatures, out of moisture.
 Continuous mixing of molasses should be done.
 If there is increase in temperature beyond 30˚C external cooling of tanks should be provided.
A temperature recorder should be provided to the tanks.
 Avoid microbiological contamination or dilution with water.
 Regular monitoring and maintenance to avoid leakages.

1.11.7 Building & workspace

 Adequate space will be provided for equipment repair or removal
 Equipment maintenance shops will be set up with appropriate safety provisions for hazards
associated with maintenance activities
  Lightning protection will be provided

1.11.8 Electric items

 Medium and high voltage cables will be completely enclosed
 Electrical equipment will be grounded adequately
 Wiring will be properly insulated, grounded, and non-exposed
 Emergency shutoff switch, clearly labeled, at all machinery units will be provided
 DG set will be provided as stand by source of power
 Maintenance tools with insulated handles will be provided

1.11.9 Fire
 The fire protection system is to provide for early detection, alarm, containment and
suppression of fires. The complete fire protection system will comprise of the following. Fire
hydrant network will be provided for firefighting in the entire project area along with
following firefighting equipment will be provided
 Different type of Fire Extinguishers, Detectors and fire Alarm shall be provided
 Fire hydrant system
 Fire Tender with chemicals foam and required arrangement for firefighting to control the
fire from the alcohol storage
 Foam system shall be contain aqueous film forming compound of 3 to 6% alcohol
resistance foam concentrated with ISI mark 4889
 Water storage Tank exclusively for firefighting operation
 Rubber mat will be used near panel area
 Periodical training to the identified supervisors and Employees in the field of Firefighting and
safety
 Emergency exits at specific locations and will be marked on the layout
 Cautionary note, safety posters, stickers will be displayed at appropriate locations
 First Aid boxes will be made available at appropriate locations
 Emergency Control Center Provision shall be made to establish an Emergency Control Centre
(ECC) from which emergency operations are directed and coordinated. This center is
activated as soon as on–site emergency is declared. ECC is equipped with adequate
communication systems in the form of telephones (Emergency telephone numbers.) and
other equipment’s to allow unhampered organizations and other nearby facility personnel.
1.12 Disaster Management Plan
1.12.1 Definition
A major emergency in a works is one, which has the potential to cause serious injury or loss of life.
It may cause extensive damage to property and serious disruption both inside and outside the
works. It would normally require the assistance of emergency services to handle it effectively.

1.12.1 Scope
An important element of mitigation is emergency planning, i.e. identifying accident possibility,
assessing the consequences of such accidents and deciding on the emergency procedures, both on
site and off site that would need to be implemented in the event of an emergency.
Emergency planning is just one aspect of safety and cannot be considered in isolation from M/s
Orange Distillery & Beverages Pvt Ltd , molasses/grain based distillery, fully endorses this fact
and hence before starting to prepare the plan, works management will ensure that the necessary
standards, appropriate to safety legislation, are in place.

1.12.3 Objective
The overall objectives of the emergency plan will be:
 To localize the emergency and, eliminate it; and
 To minimize the effects of the accident on people and property.
Elimination will require prompt action by operations and works emergency staff using, for
example, fire–fighting equipment, water sprays etc.
Minimizing the effects may include rescue, first aid, evacuation, rehabilitation and giving
information promptly to people living nearby the project site.

1.12.4 Identification of Hazards

The following types of hazards may be identified at M/s Orange Distillery & Beverages Pvt Ltd,
molasses / grain based distillery:
 Fire in Electric Panels, Oil room and Diesel storage.
 Waste treatment processes.
 Cleaning of Equipment’s and Tanks, which have held chemical substances.
To deal the above emergencies, the Emergency Plan is prepared.
1.12.5 Emergency Planning
1.12.5.1 General
Disaster Management Plan for an industrial unit is necessarily a combination of various actions
which are to be taken in a very short time but in a present sequence to deal effectively and
 efficiently with any disaster, emergency or major accident with an aim to keep the loss of men,
material, plant/machinery etc. to the minimum.
 The main functions of the Disaster Management Cell are to prepare a detailed Disaster
Management Plan, which includes:
 Identification of various types of expected disaster depending upon the type of the industrial
unit.
 Identification of various groups, agencies, departments etc. necessary for dealing with a
specific disaster effectively.
 Preparation – by intensive training of relevant teams/groups within the organization to deal
with a specific disaster and keep them in readiness.
 Establishment of an early detection system for the disaster.
 Development of a reliable instant information/communication system.
 Organization and mobilization of all the concerned departments/ organizations / groups and
agencies instantly when needed.
 A major disaster that can be expected in this proposed distillery be due to fire.

1.12.5.2 Emergency Planning for Disaster due to Fire

Cable rooms, transformer, unit, auxiliary transformers, oil tanks, etc. within the plant are the likely
areas for which disaster management plan is to be made to deal with any eventuality of fire. Stores,
workshop, canteen and administrative building will be included.

1.12.5.3 Classification of Fire

Class (A)
Fire involving combustible materials like wood, paper, cloth and bagasse etc.
Class (B)
Fire due to liquid materials like oil, diesel, petroleum products and all inflammables.
Class (C)
Fires involving domestic and industrial gases like butane and propane etc.
Class (D)
Metal fires etc.
Class (E)
Electrical fires due to short circuiting etc.
1.12.6 Need of Establishing a Fire Fighting Group

A small spark of fire may result into loss of machines and the damage by fire may high economic
losses. This type of losses can be avoided by preventing and controlling the fire instantly for which
fire–fighting group will be established.

Establish which would house and keep in readiness, the following types of equipment and
arrangements.
 CO2 extinguishers
 Dry powder chemical extinguishers
 Foam extinguishers
 80 mm. spray hoses
 Fire brigade
 Fire hydrant
 Protocol (chemical to combat oil fires).
In order to avoid fire in cable galleries, all the power and control cables of FRLS type (fire resistant
low smoke) will be used.

1.12.7 Inspection
 Fire alarm panel (electrical) will cover the entire plant. The inspection group will periodically
inspect fire extinguishers in fire stations and machines and other places.
 The groups will display emergency telephone number boards at vital points.
 The group will regularly carry out general inspection for fire.

1.12.8 Procedure for Extinguishing Fire

The following steps will be taken during a fire accident in the system:
 As soon as the message is received about fire, one of the systems will be diverted to the place
of the fire accident along with a staff member.
 Simultaneously plant fire station will be informed by phone walkie for fire brigades and fire
stations of nearby area.
 In the meanwhile, the pipe system will be operated to obtain maximum pressure on output.
In case cables are within the reach of fire, power supply will be tripped and the cables
shifted.
1.12.9 Fire Fighting with Water
Adequate and reliable arrangement is required for fighting the fire with water such as:
1. Provision for Fire brigade and Fire hydrant.
2. Arrangement of pipelines along and around all vulnerable areas.
3. Provision of valves at appropriate points to enable supply of water at the required place/area
or divert the same to another direction/pipe line.
4. Provision of overhead tanks which will be providing with the water during power failure and
it would work by the gravitational force.

1.12.10 Sources of Water for Fire Fighting

The following two sources of water have been considered for firefighting:
 Overhead Tank
 Raw Water Reservoir

1.12.11 Fire Fighting with Fire Extinguishers

To deal with fire – other than carbonaceous fires, which can be deal with by water – suitable fire
extinguishers are required to do the job effectively. It is therefore, necessary to keep adequate
number of extinguishers in readiness at easily approachable places. Adequate number of fire
stations would be installed. Further, other spray groups from the system will be diverted to the
spot.
In case of fire in the belt, belt will be cut near the burning portion to save the remaining parts.
After extinguishing the fire, the area will be well prepared for reuse.

1.13 On–Site Emergency Plan

1.13.1 Introduction
The views of the possible hazards that can arise out of the daily operations in the distillery plant,
various measures are adopted to prevent the occurrence of a major accident. This comprises of:
 Built in safety measures, alarms, trips and interlocks etc.
 Standard safe operating and maintenance procedures permit system etc.
 Training of all the involved staff in normal and emergency operating procedures.
 Training of all employees in safety, fire fighting and first aid.
However, in spite of these precautions, it is required to foresee situation of major accident and
plan for taking timely action to minimize the effects of such incident on the safety and health of
persons working in the plant as well as those living around the premises.
1.14 Preparation of Plan
1.14.1 Alarm System
A siren shall be provided under the control of Security office in the plant premises to give warning.
In case of emergencies this will be used on the instructions to shift in charge that is positioned
round the clock. The warning signal for emergency shall be as follows:
 Emergency Siren: Waxing and waning sound for 3 minutes.
 All clear signal: Continuous siren for one minute.

1.14.2 Communication

Walkies & Talkies are located at strategic locations; internal telephone system EPBX with
external P&T telephones would be provided.

1.15 Fire Protection System

1.15.1 Fire Fighting System
The fire protection system for the unit is to provide for early detection, alarm, containment and
suppression of fires. The fire detection and protection system has been planned to meet the above
objective an all–statutory and insurance requirement of Tariff Advisory Committee (TAC) of India.
The complete fire protection system will comprise of the following.

(a) Fire brigade

Automatic / manual fire detection & alarm system

(b) Fire Hydrant

Fire hydrant will be provided at all around in the plant as per TAC Norms.

(c) Portable fire extinguishers

Various areas of the plant will have one or more of the above system depending upon the
particular nature of risk involved in that area.

(d) Portable Chemical Fire Extinguishers

These are intended as a first line of defense, and hence will be stationed at strategic locations in
different buildings and also for outdoor facilities. Portable fire extinguishers will be foam type;
carbon dioxide type and multipurpose dry chemical (MPDC) type.
(e) Fire Detection and Alarm System
Fire detection and alarm system an effective means of detection, visual indication of fire location
and audible alarm of any fire at its incipient stage. This system will comprise fire alarm panels,
automatic fire detectors, manual call points and fire siren (hooter).
 The main fire alarm panel will provide both visual and audible alarm of fire in any protected areas
of the plant.

Manual break glass type fire alarms will be provided at strategic locations where high hazards
exits.
Automatic fire detectors will be provided for coal handling areas and in plant areas such as control
rooms, switchgear rooms, cable galleries etc.

1.15.2 First Aid

A first aid centre with adequate facilities shall be provided. It shall be maintained round the clock
by a compounder cum dresser and a doctor. An Ambulance shall also be provided at site to carry
affected people to hospital.

1.15.3 Security

The security requirements of the company premises shall be taken care of by CSO assisted by a Fire
In charge. The team, apart from the normal security functions will manage the role required during
a disaster management operation as a part of the crisis control team.

1.15.4 Safety
The safety wing led by a Safety Manager will meet the requirement of emergencies round the clock.
The required safety appliances shall be distributed at different locations of the plant to meet any
eventualities. Poster/placards reflecting safety awareness will be placed at different locations in
the plant area.

1.15.5 Evacuation Procedure

As the major hazard is only due to fire, which has more or less localized impact no mass evacuation,
procedures are required. Evacuation would involve only the people working very close to the fire
area.

1.15.6 Emergency Control Center

Provision is made to establish an Emergency Control Centre (ECC) from which emergency
operations are directed and coordinated. This center is activated as soon as on–site emergency is
declared.

The ECC consists of one room, located in an area that offers minimal risk being directly exposed to
possible accidents.
During an emergency, the Emergency Management Staff, including the site controller will gather
in the ECC. Therefore, the ECC is equipped with adequate communication systems in the form of
telephones and other equipment to allow unhampered organizations and other nearby facility
personnel.

The ECC provides shelter to its occupants against the most common accidents; in addition, the
ECC’s communication systems are protected from possible shutdown. The ECC has its own
emergency lighting arrangement and electric communication systems operation.
Only a limited and prearranged number of people are admitted to the ECC, when in use. This
eliminates unnecessary interference and reduces confusion.

The ECC is always ready for operation and provided with the equipment and supplies necessary
during the emergency such as:
 Updated copies of the On–site Disaster Management Plan.
 Emergency telephone numbers.
 The names, phone number, and address of external agencies, response organizations and
neighboring facilities.
 The adequate number of telephone (more than two).
 Emergency lights.
 List of fire extinguishers with their type no. and location, capacity, etc.
 Personal protective equipment.
 Safety helmets – List of quantity & location.
 Clock.
 Status boards/message board.
 Material safety data sheets for chemicals handled at the facility.
 Several maps of the facility including drainage system for surrounding area showing:
 Areas where hazardous materials are stored.
 Plot plans of storage tanks, routes of pipelines, all water permanent lines etc.
 The locations where personal protective equipment are stored.
 The position of pumping stations and other water sources.
 Roads and plant entrances.
 Assembly areas.
 Lay out of Hydrant lines.
1.15.7 Communication Equipment and Alarm Systems
This kind of equipment is absolutely vital for notifying accident; make the emergency known
both inside and outside of the facility, and coordinating, the response actions among the various
groups involved in response operations.
In particular, this equipment is used to communicate within the facility; communicate between
the facility and outside organizations; and inform the public.

Different communications systems can vary in effectiveness, depending on the task. The most
common types installed in the plant are given below.

1.15.8 Sirens
These are audible alarm systems commonly used in facilities. In case of any emergency siren will
be operated short intermittently for 1.5 minutes.

An alarm does more than just emergency warning. It also instructs people to carry out specific
assignments, such as reach to assembly point for further instructions and actions, or carry out
protective measures; this can be achieved only if the people are familiar with the alarm systems
and are trained to respond to it.

1.15.9 Personal Protective Equipment

This equipment is used mainly for three reasons; to protect personnel from a hazard while
performing rescue/accident control operations, to do maintenance and repair work under
hazardous conditions, and for escape purposes. The list of Personal Protective Equipment
provided at the facility and their locations are available in ECC.
Effective command and control accomplish these functions necessitates personal trained in this
On–site Disaster Management Plan with adequate facilities and equipment and equipment to
carry out their duties and functions.

1.15.10 Off- Site Emergency Preparedness Plan

The task of preparing the off- site emergency plan lies with the district collector. However the
off site plans will be prepared with the help of the local district authorities. The proposed plan
will be based on the following guidelines.

Plan of Co–Ordination

(A) Liaison with

1. External Authority:
 Sub Divisional Officer (SDO)
  Principal Medical Officer (PMO).
 Dy. SP.
 Fire Officer.
 Local Panchayat Officials.
 B.D.O.

 External Agencies
 Press.
 Fire Station.
 Police.
 Medical.
 Voluntary Organization.
 Railway.
 Roadways
 Private Bus Services

(B) Making plan in advance By Management and External

Authorities/Agencies Govt. Hospital.

(C) Roll and Statutory duties of outside agencies.

 Traffic Centre.
 Assisting the Medical and Evacuation team.
 Preventing unauthorised entry of personnel into the affected areas.
 Control on lookers.

(D) Duties of Public Relation officer (PRO)

 To keep liaison with Govt.
 To publish/release news in the new papers.

(E) S.D.O.
 To restore law & order.
 To help in getting aid from other Administrative Authorities.

(F) Duties of Medical Officer

 A full time Medical officer and he will discharge duties during any emergency.

He shall:
 Send the adequate medical staff to the emergency operation center for ensuring immediate
medical attention.
  Organise for transporting the injured to the hospitals wherein arrangements are made to
handle such emergencies. The nearby hospitals should be identified in advance.
 Inform all the nearby hospitals of the situation and appraise them of the antidotes that would
be necessary for treatment, if any.
 Make arrangements for requisitioning for extra ambulances for movement of the injured to
Hospital.
 Ensure that records of blood group of all employees are easily accessible and enough blood
of the specific group is available for casualties.

(G) Duties of B.D.O. (Block Development Officer)

 To control the spread of rumours.
(H) Declaring the Major Emergency
 By putting notice on notice Board.
 By publication in the News Papers.
 Announcement by P.A. System in nearby villages.
1.15.11 Procedure for Testing & Updating the Plan
Simulated emergency preparedness exercises and mock fire fighting exercises including mutual
aid scheme resources and in conservation with district emergency authority to be carried out
time to time.

1.15.12 Disclosure of Information to Worker & Public Awareness System in Existence or

Anticipated
 Safety awareness among workers by conserving various training programmes and Seminars,
competition, slogans etc.
 Practical exercise.
 Distribution and practices of safety Instructions. Safety Quiz contests.
 Display of Safety Posters & Safety Slogans.
 Developing Safety Instructions for every Job and ensuring these instructions/booklets or
manuals by the workers.

1.16 Occupational Health and Safety

Large industries, multifarious activities are involved during construction, erection, testing,
commissioning, operation & maintenance, the men, materials and machines are the basic inputs.
Along with the boons, the industrializations generally bring several problems one of them is
occupational health and safety.
 The industrial planner, therefore, has to properly plan and take the steps to minimize the
impacts of industrialization and to ensure appropriate occupational health, safety including fire
plans. All these activities again may be classified under construction & erection, and operation &
maintenance. The proposed safety plan is given below:

1.16.1 Occupational Health

Occupational health needs attention both during construction & erection and operation &
maintenance phases. However, the problem varies both in magnitude and variety in the above
phases.

1.16.2 Construction & Erection

The Occupational health problems envisaged at this stage can mainly be due to constructional
accident and noise.
To overcome these hazards, in addition to arrangements to reduce it within TLV's personnel
protective equipments shall also need to be supplied to workers.
1.16.3 Operation and Maintenance
The problem of occupational health, in the operation and maintenance phase is hearing loss due
to noise. Suitable personnel protective equipments should be given to employees.
The working personnel be given the following appropriate personnel protective equipments.
 Industrial Safety Helmet.
 Crash Helmets.
 Face shield with replacement acrylic vision.
 Zero power plain goggles with cut type filters on both ends.
 Zero power goggles with cut type filters on both sides and blue colour glasses.
 Welder's equipment for eye & face protection.
 Cylindrical type earplug.
 Earmuffs.
 Self Contained breathing apparatus.
 Leather apron.
 Aluminised fiberglass fix proximity suit with hood and gloves.
 Boiler suit.
 Safety belt/line man's safety belt.
 Leather hand gloves.
 Canvas cum leather hand gloves with leather palm.
 Electrical safety shoes without steel tie.
  Gum Boots.

1.17 Safety and Emergency Plan

Safety of both men and materials during construction and operation phases is of concern. The
preparedness of an industry for the occurrence of possible disasters is known as emergency
plan, which described as Disaster Management Plan (DMP) above. Safety requirement during
construction, operation and maintenance phases the safety policy with the following
regulations may be observed.
 To allocate sufficient resources to maintain safe and healthy conditions of work.
 To take steps to ensure that all known safety factors are taken into account in the design,
construction, operation and maintenance of plants, machinery and equipment.
 To ensure that adequate safety instructions are given to all employees.
 To provide wherever necessary protective equipment, safety appliances and clothing, and to
ensure their proper use.
 To inform employees about materials, equipments or processes used in their work, which are
known to be potentially hazardous to health or safety.
 To keep all operations and methods of work under regular review for making necessary
changes from the point of view of safety in the light of experience and aptitude knowledge.
 To provide appropriate facilities for first aid and prompt treatment of injuries and illness at
work.
 To provide appropriate instruction, training, retraining and supervision to employees in health
& safety, first aid and to ensure that adequate publicity is given to these matters.
 To ensure proper implementation of fire prevention methods and an appropriate fire fighting
service together with training facilities for personnel involved in this service.
 To ensure that professional advice is made available wherever potentially hazardous situations
exist or might arise.
 To organize collection, analysis and presentation of data on accident, sickness and incident
involving personal injury or injury to health with a view to taking corrective, remedial and
preventive action.
 To organize collection, analysis and preventive action.
 To promote through the established machinery, joint consultation in health and safety matters
to ensure effective participation by all employees.
 To publish/notify regulations, instructions and notices in the common language of employees.
 To prepare separate safety rules for each types of occupation/processes involved in a project.
  To ensure regular safety inspection by a competent person at suitable intervals of all buildings,
equipments, work places and operations.
 In operation, the safety guidelines have to be framed in consultation with manufacturer's and
be implemented.

1.18 Safety Organization

1.18.1 Construction & Erection Phase
A Qualified and Experienced safety officer has to be posted. The responsibilities of the safety
Officers include identification of the hazardous condition and unsafe acts of workers and advise
on corrective ac action, organize training programmes and provide professional expert advice
on various issues related to occupational safety and health. He is also responsible to ensure
compliance of Safety Rules/Statutory provisions.

1.18..2 Operation & Maintenance Phase

When the construction is complete the posting of safety officers shall be in accordance with the
requirement of Factories Act and their duties and responsibilities shall be as defined thereof.

1.18.3 Safety Circle

In order to fully develop the capabilities in identification of hazardous processes and improving
safety and health, safety Circle would be constituted in each area of work. The circle would
consist of 4-5 employees from that area. The circle normally shall meet for about an hour every
week.

1.19 Health and Safety Monitoring Plan

All the potential occupational hazardous workplace such as chlorine storage area, acid and alkali
storage areas will be monitored regularly. The health of employees working in these areas will
be monitored once in a year for early detection of any ailment due to exposure to hazardous
chemicals.