CHAPTER-IV

(RISK ASSESSMENT & MANAGEMENT PLAN)

4.0 DISASTER MANAGEMENT PLAN – IRON ORE MINE

It is presumed that the proposed mining process would be designed and engineered with all
possible safety measures and standard code of practices. In spite of this, there may be some
design deficiency or due to operation and maintenance faults which may lead to accidental
events causing damage to life and property. This chapter presents an over view of
environmental risk associated with various mining operations, suggested remedial measures
and on outline of the emergency preparedness plan.

4.1 Risk assessment

The objectives of environmental risk assessment are governed by the following, which excludes
natural calamites.

a. To identify the potential hazardous areas so that necessary design safety measures can
be adopted to minimize the probability of accidental events.
b. To identify the potential areas of environmental disaster, which can be prevented by
proper design of the installations and their control operations.
c. To manage emergency situation or a disastrous event, if any from the mining operation.
4.2 Identification of hazards

During the proposed operation of the open-cast mine, the following risks have been expected.

1. Filling up the mine pit due to excessive rains.

2. Failure of slope in the pit.
3. Failure of slope of external dump.
4. Fly Rock Fragment from Blasting Operations.
5. Accidents of heavy machinery.
6. Surface fire (Electrical and Oil).
7. Possible Danger due to Storage of Explosives.
4.2.1 Filling up the mine pit due to excessive rains

Filling up the mine pit due to excessive rains in the worked out area is a remote possibility.
Normally there will be sufficient warning time before such an incident takes place, harming
equipment and human life. However, as a precautionary measure, interceptor ditches along the
outer boundary of the pit area constructed to control inflow of runoff into the mine pits. Water
that collects in the mine pit from rainfall will be pumped out from the pits, using centrifugal
pumps.

4.2.2 Failure of slope in the pit

In order to allay dangers due to open cast slope failure, slope stability estimations have been
made of the existing quarries after determining various physical parameters of the ground mass
like uniaxial compressive strength, triaxial compressive strength, cohesion, angle of friction,
specific gravity of the rock, water pressure etc. Besides, all the discontinuities have been plotted
in stereo plots, which indicate that there is no chance of any planer failure or wedge failure.
Even then, factor of safety has been determined against overall slope failure as well as against
individual bench slope by circular failure, planer failure, wedge failure. Besides determining
factor of safety the slopes are monitored at regular intervals to check for any possible failure.
The well-developed drainage system over the lease area ensures that storm water does not
accumulate in the lease area and therefore hydrostatic pressure remains at a low level.

Thus all types of measurements and inspections will be carried out. The mine has been
designed based on the above considerations with sufficient safety margins to eliminate any
chances of slope failure in the pit.

4.2.3 Failure of slope of external dump

The slopes of external dumps have been initially planned at the angle of repose of dump
material. However, as the edge attain final position, the slopes will be terraced and proper
vegetation will be laid which will cause lowering of the slopes as well as binding of the soil,
preventing any slope failure.

4.2.4 Fly rock fragments and vibrations due to blasting

Trial blasting results from nearby mines have been used to arrive at the field empirical equations
based on which the charge per delay has been regulated to protect the nearby structures. All
precautions related to control of fly rock will be taken during the blasting operations. Safety zone
of 500 m as per statute shall be maintained. The nearest habitation is too far to be affected by
fly rock.
4.2.5 Accidents of heavy machinery

Most of the accidents during transfer of dumpers, trucks and other vehicles are often attributed
to mechanical failures, in which the factor of human errors cannot be ruled out. The subject
mine is a manual mine and the machinery is very less and hence the cause of accidents,

4.2.6 Surface fire

Spillage of HSD and resultant fire constitutes a potential risk. The quantity of the maximum oil,
which can spill, is not much and can be easily controlled. Sufficient numbers of portable fire
extinguishers has been provided at strategic locations to take care of any eventuality.

As soon as any fire is reported the shift-in-charge shall assume the function of disaster
controller. In case of serious fire and depending on the gravity of the situation, the Mines
Manager may be summoned to assume charge. Personnel trained in dealing with fires will be
summoned. Meanwhile the hospital will be informed to handle causalities. The fire area will be
cordoned off till the fire is fully extinguished and remain so until all wreckage and debris is
cleared away.

4.2.7 Danger due to storage of explosives

An explosive magazine exists in the mine. Adequate safety zone has been provided as per
statutory requirements while locating the magazine. The magazine has been constructed as per
plan approved by Department of Explosives. The following have been considered in the design
of the magazine.

¾ All dry vegetation within a 15 m radius cleared.

¾ Lighting arrestor installed on the magazine roof.
¾ A safety zone around the magazine created.
¾ In summer, the temperature inside the magazine is monitored to guard against
spontaneous fire.
¾ The manufacturing dates of all explosives stored in the magazine are carefully recorded
so that no explosive whose shelf life has expired is kept in stock.
In case of any fire, whosoever notices the fire will sound the alarm and inform the shift-in-
charge. The shift-in-charge will inform security personnel and arrange to evacuate all personnel,
except those who are required for fire fighting, from the area. The fire brigade shall be
summoned to deal with the emergency. Concerned district officials will be informed. Nearby
hospitals will be informed to standby to handle casualties.

4.3 Preparedness Plan

In order to take care of above hazards/disasters the following measures have been envisaged.

• Checking and regular maintenance of garland drains will be taken to avoid any in flow of
surface water into the mine pit.
• Provision of suitable capacity pumps for pumping out water from mining pit.
• Regulation 1961 will be strictly followed during all mine operations.
• Entry to unauthorized persons will be prohibited.
• Provision of all safety appliances such as safety boots, helmets Goggles etc. to the
employees and regular check for their use.
• Training and refresher courses for all employees working in hazardous places.
• Working of mine, as per approved plans and regularly updated.
• Cleaning of mine faces will be regularly done.
• Competent persons will carry out handling of explosives, charging and blasting only.
• A blasting SIREN is used at the time of blasting for audio signal.
• Before blasting and after blasting, red and green flags are displayed as visual signals.
• Warning notice boards indicating the time of blasting and NOT TO TRESS PASS are
displayed prominently.
• An approved explosive van is also available for transporting explosives to the blasting
site.
• Provision of magazine at a safe place when fencing and necessary security
arrangement.
• Regular maintenance and testing of all mining equipment as per manufacturer's
guidelines.
• Suppression of dust on haulage roads.
• Increasing the awareness of safety and disaster through competitions, posters and other
similar drives.
As a part of disaster management, a rescue team is formed by imparting specialized training to
select mining staff.

4.4 TRAINING

The training of mine personnel is conducted regularly with respect to environmental protection.
Training facilities are also extended to equipment maintenance and operation also to the
operators. Training will cover the following fields.
 ¾ Awareness regarding pollution control and environmental protection.
¾ Operation and maintenance of pollution control equipment.
¾ Afforestation / plantation and post care of plants.
¾ Field monitoring, maintenance and calibration of pollution monitoring instruments.
¾ Chemical analysis of various environmental parameters at laboratory.
¾ Repair of pollution monitoring instruments.
¾ Knowledge of norms, regulations and procedures.
¾ Occupational health and safety.
¾ Risk assessment and disaster management plan.

4.5 IMPLEMENTATION OF EMP AND MONITORING SYSTEM

4.5.1 General

Various measures have been proposed to implement for mitigating the adverse impacts due to
mining on the environment in the area. A separate wing “Environmental Management Cell
(EMC)” will be formed to look after the inspection / monitoring requirements. The mine
management will undertake the control measures in coordination with the State Forest
Department, Regional APPCB and Environmental consultant. The management of environment
shall be made an integral part of the major activities of mining.

Fig.4.1
Mines Manager Organisati
onal setup
of EMC
Geologist (Incharge of Mining Engineer /
monitoring and Asst. Manager Important
supervision)
records to
Foreman be
maintaine
d by EMC
Dust Suppression Mate
are:
Helpers
¾ Fiel
d monitoring results for air, water, meteorology
¾ Inspection records of slope failure, land erosion, drainage, socioeconomic development.
 ¾ Format to record / monitor plantation measures.
¾ Environmental and related standards / norms.
¾ Records pertaining to statutory consents, approvals
¾ Code of actions for population control in identified areas.
¾ Periodic medical examination (PME) records.
¾ Complaint register (environmental pollution)
¾ Records on water and electricity consumption
¾ Periodic progress records
¾ Environmental audit records
¾ Records of annual budgetary requirement and allocation for pollution control.

4.6 IMPLEMENTATION

The following system shall be followed to see that the environmental scheme is implemented as
per schedule.

a) A separate wing will be created to see that the engineering measures such as
construction of check dams and retention walls are taken up, wherever necessary.
b) A crew attends for afforestation measures on a regular basis for culturing, manuring and
watering.
c) On an quarterly basis, the quality of air, water, noise and soil will be monitored to
understand the status vis-à-vis the baseline data. This will enable the management for
taking up any corrective measures, if required. The frequency of sampling will be as
prescribed by the MOEF guidelines issued in this regard.
4.7 ACTIVITIES TO BE MONITORED / INSPECTED BY EMC

4.7.1 Slope failure

Regular examination will be carried out to look after for slope failure on open cast mine faces,
ore and over burden benches etc. Any abnormal condition, if observed will be brought to the
notice of concerned department. Survey team shall also monitor mine face with precision level
instruments.

4.7.2 Land erosion

Regular observations during the rainy season for checking land erosion will be made in back
filled areas / hill slopes.
4.7.3 Drainage

The effectiveness of drainage system depends upon proper cleaning of all drains and sumps.
Any blockage due to silting or accumulation of loose materials will be checked on a regular
basis. Stone pitching, brick mounds etc on drains shall also be monitored.

4.7.4 Blasting effects

Regular testing and inspection of blasting operations in work zone will be done with respect to
noise, fly rock fragments, vibration, dust and fume generation. These tests will also be
conducted whenever new pattern of blasting are adopted as per mine working.

4.7.5 Revegetation and green belt development

Planned schedule for green belt development will be checked after every year and improvement
required will be implemented. Post plantation status will be regularly checked in every season.
Phase wise development in the areas of plantation including rate of growth, survival rate etc. will
be recorded systematically.

4.7.6 Air quality monitoring

SPM, RPM, NOx and SO2 will be monitored every month in both core and buffer zones as per
the APPCB directions.

4.7.7 Water quality monitoring

Surface runoff during rainy season will be monitored for pH, TDS, SS and SO4−2 contents.
Ground water quality is monitored seasonally for the above parameters also.

4.7.8 Occupational health

Each group of mine workers undergo regular medical checkup at regular intervals by specialist
doctors.

4.7.9 Socio-economic development

As a part of the social responsibilities, the project proponent will take up the following peripheral
developmental works.

¾ Encouraging entrepreneurship among locals by vocational training.

 ¾ Upgrading one primary school.
¾ Health camps
¾ Distribution of school uniforms and books to needy students
¾ Cultural activities in the villages
¾ Provision or free Transportation of patients
¾ Preferential employment to the local people depending upon their qualification and
suitability of post.

4.8 RISK ASSESSMENT – PROPOSED BENEFICIATION PLANT

Hazard analysis involved the identification and quantification of the various hazards (unsafe
conditions) that exist in the plant. On the other hand, risk analysis deals with the identification
and quantification of risks. The workers are exposed to, accidents resulting from the hazards
due to accident occur in the plant area.

Risk analysis follows an extensive hazard analysis. It involves the identification and assessment
of risks the neighbouring populations are exposed to as a result of hazards present. This
requires a thorough knowledge of failure probability, maximum credible accident scenario,
vulnerability of population etc. Consequently, the risk analysis is often confined to maximum
credible accident studies.

In the sections below, the identification of various hazards, probable risks in the proposed plant,
maximum credible accident analysis, consequence analysis are addressed which gives a broad
identification of risks involved in the plant. Based on the risk estimation for fuel and chemical
storage Disaster Management Plan (DMP) has been prepared.

4.8.1 Approaches to the Study

Risk involved the occurrence or potential occurrence of some accidents consisting of an event
or sequence of events. The risk assessment study covers the following:

Identification of potential hazard areas.

Identification of representative failure cases.

Visualization of the resulting scenarios in terms of fire (thermal radiation) and explosion.

Assess the overall damage potential of the identified hazardous events and the impact
zones from the accidental scenarios.
 Assess the overall suitability of the site for hazard minimization and disaster mitigation
points of view.

Furnish specific recommendations on the minimization of the worst accident possibilities.

Preparation of board Disaster Management Plan (DMP), On-site and Off-site Emergency
Plan, which includes Occupational and Health Safety Plan.

4.8.2 Hazard Identification

Risk analysis and possible hazards details

Operation Process Possible Precautionary Measures to be taken

if any hazard occurs
S.No. Equipment Hazardous Measures

/areas

Heat of the 1. Fire fighting equipments 1. To switch off the

kiln powder / foam type system.
extinguishers on vehicles
and mounted on walls are 2. Fire extinguishers shall
kept readily available. immediately be used.

2. Hydrant systems provided 3. Water hose will be

at conspicuous places. operated to set out the
fire.
3. Water hose is provided.
4. Emergency alarm to be
4. No smoking zone – put on to signal the
declared. accident.
1 Rotary Kiln
5. First aid shall be
rushed to the site by the
security staff.

6. Inform the manager

present in the factory.

7. Immediate First Aid

should be given to the
victims and sent to
hospital for further
treatment.

2 Charging of coal No 1. Fire fighting equipments 1. If any worker is

 and Iron Ore to Hazardous like extinguisher and water
crusher and dryer. due to hydrogen with sufficient
automatic number of points easily
system available.
2. only trained and qualified further treatment.
people shall be appointed.
hurt/burnt in plant,
immediate first aid should
be given to the victim by
trained person and refer
to the doctor/hospital for
2. Inform the In-charge
Officer present in that
shift.

3. Information should be
given to the Plant
Manager/CIF.

Electrical Earth leakage circuit In an event of electric

Shock breaker is installed leakage main supply
3 Control Rooms possible due should be immediately
to short- shut off.
circuit.

1. Emergency kit is kept 1. Installation of inert gas

readily available in store and Nitrogen, Carbon dioxide.
working place. Equipments to take care
of fire hazards in the
2. Fire fighting equipments factory are being
powder / Foam type installed.
extinguishers on vehicle and
mounting on walls are kept 2. Hydrant point will be
readily available. for gas cylinders stores
and point where welding
Welding Gas Fire hazards 3. Hydrant system provided operation is done.
Oxygen LPG and caused by at conspicuous place.
4
/Acetylene flames and 4. Fire fighting trained man
cylinders leakage. is employed.

5. Cylinders are handled

carefully without dropping or
rolling.

6. Precaution to ensure that

cylinders are not allowed to
dash with each other.

7. Sand bed cushion

available for the purpose of
 unloading cylinders.

8. Periodic inspection done

to avoid accident of any
kind.

Shock proof insulted PCC Immediate Cut off the

Electrical Platform. power supply, treat the
power injured for electrical
shock
Electrical
5
transformer Fire fighting equipment Immediately fight fire with
available resources,
Fire I (i) Sand buckets. summon outside help if
(ii) Fire extinguisher. necessary.

Fire hazard 1. Fire proof system made Proper care is to be taken

Diesel Oil/ may be available and fighting while storing and keeping
6 Transformer Oil possible if equipment like Foam, the oil drums.
etc. storage. directly comes extinguishers and hydrant
in contact. system, etc., are kept.

1. Proper care should be Instruction Boards to be

taken while handling the displaced for knowledge
In case of chemicals. of other workers to take
bottle care of the situation in the
2. First Aid Box should be event of occurrence.
breakage,
available at Site with all
causes burns
7 Lab Chemicals necessary and required
and damage
medicines.
to respirator
systems due 3. Fire fighting equipment
to inhalation. like Extinguishers, sand
buckets should be available
always.

4.9 DISASTER MANAGEMENT PLAN – PROPOSED BENEFICIATION PLANT

The word ‘disaster” is synonymous with ‘emergency” as defined by the Ministry of Environment
and Forests (MoEF). An emergency occurring in the proposed Iron Ore Beneficiation Plant is
one that may affect several sections within it and /or may cause serious injuries, loss of lives,
extensive damage to environment or property or serious disruption outside the plant. It will
require the best use of internal resources and the use of outside resources to handle it
effectively. It may happen usually as the result of a malfunction of the normal operating
procedures.

The project is in its formative stage and detail engineering is yet to be done, so the element of
the DMP are based on concepts.

Capability of DMP

The emergency plan envisaged will be designed to intercept full range of hazards

Specific to proposed plant such as fire, explosion, major spill etc. In particular, the DMP will be
designed and conducted to mitigate those losses of containment situations, which have
potentials to escalate into major perils.

Another measure of the DMP’s capability will be to combat small and large fires due to ignition,
of flammable materials either from storage or from process streams and evacuate people from
the affected areas speedily to safe locations to prevent irreversible injury.

Emergency medical aids to those who might be affected by incident heat radiation flux, shock
wave overpressures and toxic exposure will be inherent in the basic capabilities.

The most important capability of this DMP will be the required speed of response to intercept a
developing emergency in good time so that disasters such as explosion, major fire etc. are
never allowed to happen.

Disaster Contorl Philosophy

The principa l strategy of DMP is “prevention” of identified major hazards. The “Identification” of
the hazards will employ one or more of the techniques {e.g.Hazard and Operability Study
(HAZOP), accident consequence analysis etc}. Since these hazards can occur only in the event
of loss of containment, one of the key objectives of technology selection, project engineering,
construction, commissioning and operation is “Total and Consistent Quality Assurance”. The
Project Authority will be committed to this strategy right from the conceptual stage of the plant
so that the objective of prevention can have ample opportunities to mature and be realized in
practice.

The DMP or Emergency Preparedness Plan (EPP) will consist of

 On-site Emergency plan

Off-site Emergency plan

Disaster Management Plan preparation under the headlines of On-site Emergency plan and Off-
site Emergency plan is in consonance with the guidelines laid y the Ministry of Environment and
Forests (MoEF) which states that the “Occupier” of the facility is responsible for the
development of the On-site Emergency plan.

The Off-site Emergency Plan should be developed by the Government (District Authorities)

4.9.1 On-Site Emergency Plan

Objectives

The Objective of the On-site Emergency plan should be to make maximum use of the combined
resources of the plant and the outside services to

1. Effect the rescue and treatment of casualties.

2. Safeguard other personnel in the premises.
3. Minimize damage to property and environment.
4. Initially contain and ultimately bring the incident under control.
5. Identify any dead
6. Provide for the needs of relatives.
7. Provide authoritative information to the news media
8. Secure relevant records and equipment for the subsequent enquiry into the
cause and circumstances of emergency.
Action plans

The Action Plan should consist of:

1. Identification of Key Personnel

2. Defining Responsibilities of Key personnel
3. Designating Emergency Control Centers and Assembly points.
4. Declaration of Emergency
5. Sending All Clear Signal
6. Defining actions to be taken by non-key personnel during Emergency.
Key Personnel

The actions necessary in an emergency will clearly depend upon the prevailing circumstances,
Nevertheless, it is imerative that the required actions are initiated and directed by nominated
people, each having specified responsibilities as part of co-ordinated plan. Such nominated
personnel are known as Key Personnel.

The Key Personnel are:

1. Site Controller (SC)

2. Incidental Controller(IC)
3. Liaison and Communication Officer (LCO
4. Fire and Security Officer (FSO)
5. Team Leaders(TL)

Site Controller (SC)

In the emergency situation, decisions have to be taken which may affect the whole or a
substantial part of the plant and surrounding area. Many of these decisions will be taken in
collaboration with the other officers at the plant and the staff. It is essential that the authority to
make decision be invested in one individual. In this plan, he is referred to as the ‘Site Controller’.
The Plant Manager (however called) or his nominated deputy will assume responsibility as SC.

Incident Controller (IC)

In the emergency situation, someone has to direct the operations in the plant area and co-
ordinate the actions of outside emergency services at the scene of incident. The one who will
shoulder this responsibility is known as ‘Incident Controller’ in this plan.

A Senior Operations Officer or an officer of similar rank of the unit may be nominated to act as
the IC.

Liaison and Communication officer (LCO)

Operations Officer or any other officer of deputy rank will work as LCO and will be stationed at
the main entrance during emergency to handle police, Press and other enquiries. He will
maintain communication with the IC
Fire and Safety officer (FSO)

The Fire and Safety Officer will be responsible for fire fighting. On hearing the fire alarm he shall
contact the fire station immediately and advise the security staff in the plant and cancel the
alarm. He will also announce on PAS(Public Address System) or convey through telephones or
messengers to the SC, IC and LCO about the incident zone. He will open the gates nearest to
the incident and stand by to direct the emergency services. He will also be responsible for
isolation of equipment from the affected zone.

Team Leader (TL)

A number of special activities may have to be carried out by specified personnel to control as
well as minimize the damage and loss. For this purpose designated teams would be available.
Each team will be headed by a Team Leader (TL)

Following teams are suggested:

1. Repair Team
2. Fire Fighting Team
3. Communication Team
4. Security Team
5. Safety Team
6. Medical Team
Responsibilities of Key Personnel

Site Controller (SC)

1. On getting information about emergency, proceed to Main Control Centre

2. Call in outside emergency services
3. Take control of areas outside the plant, which are affected
4. Maintain continuous communication, review situation and assess possible course
of events.
5. Direct evacuation of nearby settlements, if necessary
6. Ensure that casualties are getting enough help
7. Arrange for additional medical help and inform relatives
8. Liaison with Fire and Police services and provide advice on possible
9. Effects on outside areas
10. Arrange for chronological recording of the emergency
 11. where emergency is prolonged, arrange for relieving personnel, their catering
needs etc.
12. Inform higher officials in head office
13. Ensure preservation of evidence
14. Direct rehabilitation work on termination of emergency
Incident Controller (IC)

1. On getting emergency information, proceed to Main Control Centre.

2. Activate emergency procedure such as calling in various teams
3. Direct all operations within plant with following priorities:
a) Control and contain emergency
b) Secure safety of personnel
c) Minimize damage to plant, property and the environment
d) Minimize loss of material
e) Direct rescue and repair activities
f) Guide fire-fighting teams
g) Arrange to search affected area and rescue trapped persons
h) Arrange to evacuate non-essebtuak oersibbek ti safe area/assembly
point.
i) Set up communications network and establish communication with SC
j) Arrange for additional help/equipment to key personnel of various teams
k) Consider need for preserving all records, information for subsequent
enquiries
Liaison and Communication Officer

1. To ensure that casualties receive adequate attention, arrange additional help if

required and inform relatives
2. To control traffic movements into the plant and ensure that alternative transport is
available when need arises
3. When emergency is prolonged, arrange for the relief of personnel and organize
refreshments/catering facility
4. Advise the Site Controller of the situation, recommending (if necessary) evacuation
of staff from assembly points.
 5. Recruit suitable staff to act as runners between the Incident Controller and himself if
the telephone and other system of communication fail. Maintain contact with
congregation points
6. Maintain prior agreed inventory in the control room
7. Maintain a log of the incident on tape
8. In case of a prolonged emergency involving risk to outside areas by wind blown
materials- contact local meteorological office to receive early notification of changes
in weather conditions.
Fire and Safety Officer

1. Announces over the PAS in which zone the incident has occurred and on the advice of
the Shift Officer informs the staff to evacuate the assembly
2. Inform the Shift Officer In-charge, if there is any large escape of products.
3. Call out in the following order:
a) Incident Controller or his nominated deputy
b) Maintenance Officer
c) Personnel and Administrative Officer
d) Departmental Head in whose area the incident occurred
e) Team Leaders(TL)
Emergency Control Centre

The Emergency Control Centre will be the focal point in case of an emergency from where the
operations to handle the emergency are directed and coordinated. It will control site activities.

Emergency management measures in this case have been proposed to be carried from single
control centre designated as Main Control Centre (MCC)

MCC is the place from which messages to outside agencies will be sent and mutual aids and
other helps for the management of emergency will be arranged. It will be located in the sage
area. It will be equipped with every facility for external and internal communication, with relevant
data, personal protective equipments to assist hose manning the centre to enable them to co-
ordinate emergency control activities. CC will be attended by SC.

Following facilities would be available in the MCC:

• P &T phones, mobile phones, intercoms, and wireless

 • Fax and telex
• Emergency manuals
• Blown up area maps
• Internal telephone directories
• District telephone directories
• Emergency lights
• wind direction and speed indicator
• Requisite sets of personal protective equipment such as gloves, gumboots and aprons
MCC will be furnished with call out list of key persons, fire, safety, first aid, medical, security,
police and district administrative authorities. MCC will also contain safety data pertaining to all
hazardous materials likely to cause emergency and well-defined procedures of fire fighting,
rescue operations, first aid etc.

Assembly point

In an emergency, it will certainly be necessary to evacuate personnel from affected areas and
as precautionary measure, to further evacuate non-essential workers, in the first instance, from
areas likely to be affected, should the emergency escalate. The evacuation will be effected on
getting necessary message from i.e. on evacuation, employees would be directed to a
predetermined safe place called Assembly Point.

Proposed Location: Area opposite to service building will be the Assembly Point where all non-
key personnel would assemble on getting direction over Public-Address System.

Outdoor assembly points, predetermined and premarked, will also be provided to accommodate
evacuees from affected plant area(s). Roll call of personnel collected at these assembly points,
indoor and outdoor will be carried out by roll call crew of safety team to account for any missing
person(s) and to initiate search and rescue operations if necessary.

Declaration of Emergency

An emergency may arise in the terminal due to major leakage of oil or major outbreak of
fire/explosion. In case of major leak or major outbreak of fire the state of emergency has to be
declared by the concerned by sounding Emergency Siren.

Upon manual or sensor detection of a major loss of containment of volatile hazardous

substance, the DMP is activated by raising an audible and visual alarm through a network of
geographically dispersed gas/vapour and heat detectors and also “break glass” type fire alarm
call points with telephone hand sets to inform the Central Control Room.

A separate siren audible to a distance of 5 km range will be available for this purpose. The
alarm is coded such that the nature of emergency can be distinguished as a leakage or major
fire.

The Control Centre and Assembly point will be located at an area of the minimum risk or
vulnerability in the premises concerned, taking into account the wind direction, areas which
might be affected by fire/explosion, leakage etc.

After cessation of emergency, FSO will communicate to IC. After verification of status, IC will
communicate with SC and then announce the “All Clear” by instructing the Time Office to sound
the “All Clear Signal”.

Alarms would be followed by an announcement over Public Address System (PAS). In case of
failure of alarm system, communication would be’ by telephone operator who will make
announcement in the complex through PAS. Walkie-talkie system is very useful for
communication during emergency with predetermined codes of communication. If everything
fails, a messenger could be used for sending the information. Two 5 km, range variable pitch
electric sirens (one in service and the other standby) will generate the main alarm for the entire
site as well as for the district fire brigade. The alarm is coded such that the nature of emergency
can be distinguished as a leakage of major fire. Fire and Gas alarm matrices are provided at the
Central Control room, security gate, on-site fire station and main administrative office corridor to
indicate location of the site of emergency and its nature.

Mutual Aid

Procedure

All factories may not be equipped with an exhaustive stock of equipment/materials required
during an emergency. Further, there may be a need to augment supplies if an emergency is
prolonged.

It would be ideal to pool all resources available in the and nearby outside agencies especially
factories during an emergency, for which a formal Mutual Aid scheme should be made among
industries in the region.
Essential Elements

Essential elements of this scheme are given below:

• Mutual aid must be a written document, signed by Location In-charge of all the industries
concerned
• It should specify available quantity of materials/ equipment that can be spared (not that
which is in stock)
• Mode of requisition during an emergency.
• It should authorize the shift-in-charge to quickly deploy available material/equipment
without waiting for formalities like gate pass etc.
• It should spell out mode of payment/replacement of material given during an emergency
• It should specify key personnel who are authorized to requisition materials from other
industries or who can send materials to other industries
• It should state clearly mode of receipt of materials at the affected unit without waiting for
quantity/quality verification etc.
• Revision number and validity of agreement should be mentioned
• This may be updated from time to time based on experience gained

Emergency Management Training

• The Key Personnel would undergo special courses on disaster management. This may
preferably be in-plant training. The Managers, Senior Officers and Staff would undergo a
course on the use of personal protective equipment.
• The Key Personnel belonging to various Teams would undergo special courses as per
their expected nature of work at the time of emergency.
• The plant management should conduct special courses to outside agencies like district
fire services to make them familiar with the plant layout and other aspects, which will be
helpful to them during an emergency.
Mock Drills

• It is imperative that the procedures laid in this Plan are put to the test by conducting
Mock Drills. To avoid any lethality, the emergency response time would be clocked
below 2 minutes during the mock drill.
• 1st Step: Test the effectiveness of communication system
• 2nd Step: Test the speed of mobilization of the plant emergency teams
 • 3rd Step: Test the effectiveness of search, rescue and treatment of casualties
• 4th Step: Test emergency isolation and shut down and remedial measures taken on the
system
• 5th Step: Conduct a full rehearsal of all the actions to be taken during an emergency
The Disaster Management Plan would be periodically revised based on experiences gained
from the mock drills.

Proposed Communication System

The instrument and control system will take care of the following operating philosophy of the
plant

• The project will be provided with a control system located in a central control room.
• The shift engineer will operate the plant from his console panel.
• All operations will be represented in a graphic panel on the console and every operation
will be depicted as operating sequences.
• All operating parameters will be displayed in digital format.
• Alarms will be provided for all parameters, when they exceed set values.
• High-High/Low-Low alarms and trip functions will be provided to trip
• Pumps/compressors to bring the entire system to a safe shutdown.

Proposed Fire Fighting System

Elaborate fire fighting system will be available for fighting fires in any corner of the plant. A
comprehensive fire detection and protection system is envisaged

• Fire water storage tanks of adequate capacity.

• Fire water pump house containing combination of diesel and electrically driven pumps.
• Hydrant system complete with suitable size piping, valves, instrumentation, houses,
nozzles, hose boxes/stations, monitors etc.
• Foam injection system for fuel oil/storage tanks consisting of foam concentrate tanks,
foam pumps, in-line inductors, valves, piping and instrumentation etc.
• Automatic high velocity water spray system consisting of detectors, deluge valves
projectors, valves, piping and instrumentation.
• Automatic high velocity water spray system consisting of QB
 • Detectors/smoke detectors, linear heat sensing cable detectors, deluge valves, isolation
valves, nozzles, piping instrumentation etc.
• Suitable “Halon Substitutes” such as INERGEN or FM..200 or AGGONITE for protection
of control room, equipment room, computer room and other electric and electronic
equipment rooms.
• Computerized analogue, addressable, early warning type fire detection and alarm
system consisting various types of fire detection such as ionization type smoke detection
system, photo electric type smoke detection system, linear heat sensing cable detector,
quartzoid bulb (QB) heat detection system, infrared heat detectors and spot type
electrical heat detectors.
• Portable and mobile extinguishers, such as pressurized water type, carbondioxide type,
foam type, dry chemical powder (DCP) type located at strategic locations throughout the
plant.]
• Fire tenders/engines of water type, DCP type/foam type, trailer pump with fire jeep
etc.provided in the fire station.
• Complete instrumentation and control system for the entire fire detection and protection
system for safe operation of the complete system.
Other safety Measures

Considering that fire and explosion is the most likely hazard in such installations, the plant is
being provided with systems to guard against such hazards. Salient among these are:

• A proper layout to prevent and minimize the effects of any hazardous situation
• Design of storage vessels and all components to codes and standards to withstand the
rigorous duty
• Provision of operating systems to conduct the process through well established safe
operating procedures
• A control system, which monitors all, plant parameters and give alarms
• Control system, which has trip provisions to prevent hazard conditions escalating
• A gas detection system which will provide early warning of any leaks
• Provision of a fire protection system to control fire
• Provision of flame-proof lighting system in the fire prone areas
Proposed First Aid and Medical Facilities

The First Aid Medical Centre has been proposed. It will be fully equipped with emergency
facilities. It will be open round the clock. A Medical Officer with Compounder will always be
available in the centre. Emergency cars will be available in all the shifts. Adequate number of
first aid boxes will be kept at strategic locations. Required stock of first aid medicines will be
maintained. Trained first aiders will be available in all departments.

Facilities to be kept in the Medical Room along with others will include: Oxygen Cylinders,
Injection Coramine, Glucose Saline, LV. Sets, Syringes, Injection Needles, Stretchers and
medicines.

Proposed Emergency Power Supply

Strategic areas will be provided with emergency lights fed through stationed battery system.
Portable emergency lamps will be also available at required points. A Diesel Driven Generator
of adequate capacity will be available to keep the operations running in case of power failure.
Diesel Engine operated fire pumps will be available.

4.9.2 Off Site Emergency Plan

Objective

If the effects of the accident or disaster inside the plant are felt outside of its premises, it calls for
an off-site emergency plan, which should be prepared and documented in advance in
consultation with the District Authorities.

Key Personnel

The ultimate responsibility for the management of the off-site emergencies rests on the
Collector / District Magistrate / Deputy Commissioner. He will be assisted by representatives
from all concerned organizations, departments and services at the District level. This core group
of officers would be called the District Crisis Management Group (CMG). The members of the
group will include:

1) Collector/District Magistrate Deputy Commissioner

2) Commissioner of Police
3) Municipal Commissioner, if municipalities are involved
4) Deputy Director, Health
 5) Pollution Control Board Representative
An Operation Response Group (ORG) will then be constituted to implement the directives of the
CMG.

The various government departments, some or all of which will be concerned, depending on the
nature of the emergency, could include:

• Police • Animal Husbandry

• Health & Fami Welfare • Agriculture

• Medical • Civil Defense

• Revenue • PWD

• Fire Service • Civil Supplies

• Transport • Panchayats

• Electricity
The SC and IC, of the on-site emergency team, will also be responsible for communications with
the CMG during the off-site emergency.

Education to Public

People living within the influence zone should be educated on the emergency in a suitable
manner. This can be achieved only through the Local and District Authorities. However, the
Project Authority can extend necessary information to the Authorities.

4.9.3 Disaster Management Plan for the Beneficiation Plant

The main objectives of this disaster management plan are to:

• To identify type of major disaster which may occur in the plant

• To prepare an action plan to handle disaster.
Identified Areas where disasters can occur

• Rotary kiln
• Bucket elevator
• Auto Loading & Unloading Section
• Electrical premises
 ™ Electrical room
™ Transformer area
™ Cable tunnel
• Other premises
All operating facilities and storage facilities for raw materials like coal, fuel oil etc

Severity of accidents have been categorized as Category I – Operator Level and Category II
– Local / Community Level

Category–I

In category-I, disasters may occur due to fire, explosion, oil spillage, mall function of the
machines and spontaneous ignition of inflammable materials. The severity of this category
depends upon the disaster type and nature of it. It may affect the work force health that involves
the operation at that facility and even may be on the facilities of the plant.

Category–II

In case of complete failure of all automatic control / warning systems of the different units then it
may leads to disaster which may have the high severity on inside work force and facilities of its
own and even may effects on the others facilities surrounding plant. Probability of these
disasters occurrences will be very less because of the plant alternative systems and well
qualified and trained work force which will be placed in respective areas.

Disaster Preventive Measures

• Design, construction of all facilities and machineries will be as per national and
international codes as applicable in specific cases and lay down by statutory authorities
• The operations of the plant will be as per applicable standards laid by the statutory
authorities
• Provision of adequate access ways for the movement of equipment and work force will
provide
• Minimum two numbers of gates for escape during disaster will take place
• All the storage facilities will be marked properly and protected by providing the fencing
around to the storage systems
• Water spraying in coal storage facility
• Well established fire fighting system
Safety and Training

In the plant all the workforce will be provided with necessary safety protective equipments.
Instrument the like safety valves, safety controls system. Safety department will look after the
safety awareness programs by different means like posters, messages on the notice boards, etc
and safety trainings in the plant as per requirement of the criticality. Safety training and practical
demos to the selected individuals in each department will provided.

Functions of Disaster Controller

• To declare “Disaster Emergency” after consulting the Sr. Officer available and inform
Fire Station Control Room to sound the sirens accordingly and arrange to convey the
message in public addresses system
• To report to DCR immediately
• To receive message from the communication centre
• To take decision in consultation with the commanding Officer of different services and
convey them to the disaster point
• To be responsible for planning and provision of assistance from township and from local
authorities
• Decision of the Disaster Controller on any matter will be final to met the objective of
disaster control plan.
• To assist Disaster Controller for provision of material and man power concerning his
services
• To convey message to his services team through communication centre after consulting
Disaster Controller
• To consult between themselves on matters related to more than one services and to
decide on the action to be taken

Repair Services

This section will look after mainly for the following areas after disaster takes place.

• To take up quick repairs of the damaged machinery

• To take up repair of damaged building roads and culverts.
• To maintain essential public utility services viz. water, electricity and sewages system.
Traffic Control

During the disaster, the movement of the safety vehicles and fire fighting vehicles will be
monitored and make the emergency ways to be free from vehicles to attend the disaster works
by the security of the plant. Persons arriving by motor transport at the location of fire /
emergency must not park their vehicle within 100 meters of fire, near fire hydrants, at road
junction and at access roads. The ignition key should be left in the vehicles.

Security Services

In the plant security department will be responsible for the plant security by keeping security
checks at different locations based on the sensitivity of the area. During the disasters the
functions of security will be follows:

• Alter the all workforce about the disaster and its location
• Update the developments and status of the disaster to the higher officials to take
necessary actions
• Co-ordinate the disaster status to the local authorities to get necessary support for them
• Control the vehicular traffic inside the plant to get way to the safety and fire fighting
vehicles to attend the disaster works immediately
• Assist the different divisions like fire fighting, safety, local authorities etc. to make the
process easy to handle the disaster works