Fauregzlusm 14320326 Risk Assessment Report

RISK ASSESSMENT REPORT
of
Proposed Integrated Cement Project - Clinker (3.0

MTPA), Cement (4.8 MTPA), Captive Power Plant (48
MW) and WHRS (15 MW) At Village: Kotapadu,
Mandal: Kolimigundla, District: Kurnool (Andhra
Pradesh)
By
M/s. PRISM JOHNSON LIMITED

Proposed Integrated Cement Project - Clinker (3.0 MTPA), Cement (4.8 MTPA), Captive Power Plant (48 MW) and WHRS (15 MW)
At Village: Kotapadu, Mandal: Kolimigundla, District: Kurnool (Andhra Pradesh)
1.1 RISK ASSESSMENT AND DISASTER MANAGEMENT PLAN

1.1.1 Risk Assessment & Damage Control
Risk assessment is the determination of quantitative or qualitative value of risk related to a concrete
situation and a recognized threat.
Accidental risk involves the occurrence or potential occurrence of some accident consisting of an
event or sequence of events resulting into fire, explosion or toxic hazards to human health and
environment.
Activities requiring assessment of risk due to occurrence of most probable instances of hazard and
incident are both onsite and off-site.
Figure: 1: Risk Analysis Strategy
1.1.2 Hazard Identification & Risk Assessment (HIRA) for Integrated Cement Project
Hazard Identification and Risk Analysis (HIRA) is a collective term that encompasses all activities
involved in identifying hazards and evaluating risk at facilities, throughout their life cycle, to make
certain that risk to employees, the public, or the environment are consistently controlled within the
organization’s risk tolerance. These studies typically address three main risk questions to a level of
detail commensurate with analysis objectives, life cycle stage, available information and resources.
A thorough Hazard Identification and Risk Analysis, or risk system is the core element in the RBPS
pillar of understanding hazards and risk. The cement manufacturing industry is labor intensive.
Cement industries experiences risk of a number of hazards inherent to the cement production
process. The possible area, places, type of likely hazards identified are as under in Table - 1.
Table - 1
The possible area, places, type of likely hazards identified
Department / Location Activity Hazards / Impact
Mines Mining Inundation / Sudden in rush of water
M/s. Prism Johnson Limited 1

Department / Location Activity Hazards / Impact

Magazine Storage if Explosive Fire & Explosion
HEMM Workshop Storage of Diesel, Lubricating oil Fire & Air Pollution
Reclaimer & stacker Stacker & reclaimer engulfment in pile Fire
Storage of Raw Mill in silo & operation of Fire, Collapse, Material spillage and
Raw Mill
ESP explosion
Cleaning of jamming in preheater /kiln Backfire result in burnt/injuries to
Pre-heater & Kiln
inlet working people
Kiln girth gear Use of oil & grease Fire
Coal grinding and storage of fine coal in Fire & explosion in bag filter and
Coal Mill
coal bins material spillage
Coal Handling Stacking of coal in open yard Fire
Belt conveyer Coal Handling Fire
Clinker Silo Storage of Clinker Collapse and Material spillage
Compressor house Operation of compressor Fire & explosion
Pressure Vessels Storage of Compressor air Explosion
Storage of oil drum, waste oil drums and
Store & scrap yard Fire & explosion
DA Cylinders
Electrical Transformer, MCC / Sub station Fire & explosion
Store Storage of lubricating oil Fire
Storage of packing bags, Storage of Fire, Collapse, Material spillage and
Packing plant
cement in Silos explosion
Storage of Alternative Fuel resources Fire / Spillage of hazardous material
AFR Storage area
(AFR) & Hazardous material leaching
Table - 2
Hazard Identification and Risk Assessment (HIRA) and Safety measures to be adopted at Cement Plant
S. No. Possible Hazard Cause of Hazard Safety Measures
1. Exposure to High Temperature Carelessness during working • Shielding surfaces where workers
• Handling of hot raw meal hours, Damage of proximity and close contact with hot
(Powdered limestone, equipment/tools equipment is expected,
laterite additives etc. • Using personal protective equipment
heated in a pre-heater (PPE), as needed (e.g. insulated gloves
cyclone). and safety helmet & safety shoes);
• Handling of hot clinker. • Water arrangement at site;
• Operation & maintenance • Minimizing the work time required in high
of kiln or other hot temperature environments by
equipment implementing shorter shifts at these
locations.
2. Physical Hazards
• Falling / impact with • Slips, Trips and fall. • It will be personally ensured that the
objects. • Contact with falling / equipment’s with moving parts are de-
• Hot Surface burns moving objects and energized, isolated and locked/tagged
• Transportation Lifting/ over exertion. out.
• Work permit for work at height


• Contact with allergic • Contact with, or capture • Fall protection system will be used by
substances in, moving machinery. workers working at an elevation more
• Maintenance of than or equal to 6 feet.
equipment, including mills, • PPEs will be provided to the person
mill separators, fans, dealing with flame welding, cutting or
coolers, and belt brazing.
conveyors, • Safety helmets will be provided to
workers for protection from any falling
accidents.
• Barriers will be provided to prevent
slipping or being knocked off the edge of
a structure.
• Danger areas will be marked clearly with
suitable warning signs to avoid any
accident.
• Proper medical care will be provided at
the project site in case of any accidental
issues.
3. Events Pertaining to Manufacturing Process
i. Handling of Coal • Flammable, ignitable and • The coal will be received and stored in
reactive property of fuel. Stockpile.
• Stockpile will be made in a way so that the
wind strikes the width of the stockpile and
not the length.
• Freshly mined coal will not be piled over
the old coal and the old coal will be used
first.
• Stacking- layer by layer (each of 1 to 1.5 m
height) with compaction of each layer will
be done.
• Stacking in small heaps will be done and
compacted in trapezoidal shape.
• Effective sprinkling systems will be
provided all round the coal storage yards.
ii. Handling of Alternative fuel & • Material Spillage. • Storage area will be designed to withstand
Raw Materials (AFR) • Flammable, ignitable and the load of material stocked and any
reactive property of fuel. damage from the material spillage.
• Adequate firefighting systems will be
provided for the storage area, along with
the areas in the facility.
iii. Handling of Fine dust Maintenance process in the • The relevant PPEs will be provided during
pre-heater cyclone and other cleaning to the workers with sufficient
areas care during the maintenance operations
iv. Handling of Hot Clinker Spill out of hot clinker during • Proper care for the conveyor system and
transportation to the top of the bund wall for the clinker stock pile will
be the part of design criteria


the silo or closed stock pile for
storage
v. Handling of Cement During material transfer • Cement will be conveyed in a closed circuit
(mechanical and/or pneumatic or
combination of both) to avoid any health
and environment risk.
4. Fire Fuel Spillage, Electrical rooms, • Installation of Fire detection alarm and
Transformer area, AFR Storage control system for early detection
area, Empty bag go-down, • Suitable fire extinguishers, fire hydrant
Diesel Storage tank and system and fire buckets etc. will be
Flammable gas cylinder provided for fighting the fire during
storage area. emergency.
• Employees working in such areas will be
imparted training for first aid firefighting
to prevent/extinguish the fire at initial
stage.
5. Explosion Heat and Pressure load due to • Proper isolation of system.
damage in equipment/ tool • All cylinders to be secured.
• 8 Flash back arrestor to be use between
the cylinder & torch.
• Hoses in good condition.
• Proper PPE.
• Correct Fire extinguisher to be available at
site.
• Deployment of Experienced personnel.
• Inspect the cylinders & hoses before
starting the job.
6. Electrocution Carelessness during working • Proper care will be taken while working on
hours, Damage of such equipment’s.
equipment/tools • Proper earthing of panel must be checked.
• Correct Fire Extinguisher to be available at
site.
1.3.1 Natural and Manmade Calamities which can lead to Emergency
S. No. Calamity / Activity Mitigation Measures
1) Earthquake • Construction of buildings as per IS 1893 Part 4:2005 Criteria for Earthquake
Resistant Design of Structures (Industrial Structures Including Stack-Like
Structures) and IS 13920:1993 Ductile Detailing of Reinforced Concrete
Structures Subjected to Seismic Forces to minimize the risk of Seismic loads.
• Identification and Constitution of Emergency Response Team.
• Equipping the Control Centers with Communication facilities, emergency
vehicles, emergency contact and supplies, etc.
• Assembling of persons at emergency assembly points will be ensured during
emergency

S. No. Calamity / Activity Mitigation Measures

• Shut down of plants will be ensured and first aid to victims will be provided.
2) Storm and Lightning • Regular contacts will be established with local meteorological department.
• The factory operations installations will be appraised.
• Availability of tools, batteries, non-perishable other materials that might be
required will be checked.
• All the systems will be shut down; metallic sheets, loose material, empty drums
etc., will be secured properly.
• Drainage Systems will be flushed down properly.
• Do not seal the office completely as the suction created by the difference in
atmospheric pressure inside and outside can rip open a window or door by
breaking window glass panes
• Take special precautions in driving vehicles since the under-pavement could cave
in due to the weight of automobile
3) Flood • HFL alarms will be provided.
• Nallahs will be monitored by supervisors in all shifts.
4) Air Raid • Air raid warning will be obtained from District Emergency Authority or Defense
Authorities, during which total blackout of the entire complex should be
considered.
• Aviation lights, Street lights, Plant lightning will be switched off.
• Brown curtains will be provided for all windows inside building.
5) Food and Water • Medical Officer will be immediately informed by Senior most person available at
Poisoning site.
• Adequate inventory/ supply of medicines, saline water etc. will be maintained
and Impart awareness as well as training regarding food/ water poisoning will
be provided.
• Contaminated Source will be identified and seized to avoid its further circulation
and alternate supplies will be arranged.
• Detailed epidemiological investigation to identify cause of contamination will be
conducted.
Hazard Identification & Risk Assessment (HIRA) - Cement Manufacturing process -

Chapter - 7 of Final EIA / EMP Report
Activity/Products Locati Severity Probability of Risk

Hazards Risk Control & Influence
/Services on (5) Occurrence (5) Rating
Occupational illness Isolate inlet chute and Use of PPE
Asphyxiation needing hospitalized 2 2 4
treatment
Spillage of dust & Eye and body injury and Use appropriate PPE's
3 3 9
material requiring Hospitalization.
Raw
Huge spillage of Allot trained workmen, Toolbox talk before job, Use of PPE
All Hopper Fatal Injury Mill & 5 1 5
material / Silo and Follow as per work permit
Cleaning Coal
Injury Requiring Allot trained workers, Use of PPE and Follow as per work
Injury to hand Mill 2 4 8
Hospitalization. permit
Collapse of material Allot trained workers, Use of PPE and Follow as per work
Fatal Injury 5 1 5
leading to entrap permit
Sudden Inflow of Allot trained workmen, Toolbox talk before job, Use of PPE
Fatal Injury 4 1 4
material and Follow as per work permit
o While opening the pocking hole person shall not stand in
front of the pocking hole, SOP to be followed and
appropriate PPEs to be used.
Spillage of Hot meal Injury leading to o Person should not be in front of hole and no body stand
outside cyclone and Permanent disability, 4 3 12 bottom of that area, SOP to be followed and appropriate
Puffing of hot air Loss of body parts, Burns Pre- PPEs to be used.
Cyclone jam
heater o Combustible & flammable materials to be
removed/protected and firefighting equipment to be
available at site.
1. Area below jam cyclone floors to be cordoned. 2.
Hot material falling
Fatal 5 2 10 Experienced people only allowed for jam removal and SOP to
on persons
be followed
Injury leading to Draught & temperature of system & Process Controls and use
Kiln inlet & Raiser Splash of hot
Permanent disability, 4 2 8 appropriate PPE's
duct cleaning material
Loss of body parts, Burns


Rebound of hot Draught & temperature of system & Process Controls and use
Injury leading to Burns 3 2 6
coating pieces appropriate PPE's
Injury leading to burn & 1) Maintain the kiln hood draft higher side. 2) Blaster to be
Burn injury 4 3 12
partial disability switch off & empty out. 3) Use appropriate PPE's.
Injury leading to 1) Keep one person nearer to UT Pump for emergency. 2) All
Cooler Snow man Water hose hit to
Permanent disability, Cooler 5 2 10 pipe joints to be checked on routine basis. 3) Pressure to be
removal the person
Loss of body parts, Burns maintained for safe job execution.
Hot material Injury leading to burn & 1) Use appropriate PPE's. 2) Workmen should not stand in
4 3 12
bounce partial disability front of poking hole & maintain safe distance.
Injury leading to 1) Keep one person nearer to UT Pump for emergency. 2) All
Damaged or
Permanent disability, - 5 2 10 pipe joints to be checked on routine basis. 3) Pressure to be
bursting the hoses
UT pump Loss of body parts. maintained for safe job execution/ under the capacity.
operation Injury leading to 1) Keep one person nearer to UT Pump for emergency. 2) All
Water hose hit to
Permanent disability, - 4 2 8 pipe joints to be checked on routine basis. 3) Pressure to be
the person
Loss of body parts. maintained for safe job execution/ under the capacity.
Removal of hot 1) Inlet slope area coating to be removed. 2) Kiln inlet seal to
Injury leading to
dust material Flush / Emission of be checked. 3) Kiln inlet draft to be maintained to higher side.
Permanent disability, - 5 3 15
from kiln inlet hot material 4) Water Spray to be done on spilled hot material from a safe
hot dust area distance and then remove. 5) Use appropriate PPEs.
PH, Inspect all cyclones before entering into kiln/cyclone, if there
Kiln is any coating then remove the coating. Provide the dummy
Scaffolding for Injury leading to burn &
Dust emission inlet, 4 3 12 above the working area. Close Supervision and Monitoring
process activities partial disability
outlet, with safety personal. Scaffolding material changed from
(PH Kiln inlet,
kiln wood & rope to MS pipe & clamps for avoiding slippage.
outlet, kiln hood,
Injury leading to hood Close all air blasters, vent out the residual air if any. Keep the
cooler)
Body Injury permanent disability, & 5 3 15 vent valve open.
Loss of body parts, cooler


Injury leading to Ensure all coating, accumulations removed from the
Person may fall,
permanent disability, 5 2 10 cyclones. Trained workmen to be deployed. Use appropriate
material may fall
Loss of body parts, PPEs (Full Body Harness,)
Injury leading to Clear the coating or accumulation before entering in to the
Material may flush
permanent disability, 5 2 10 cyclone and provide dummy in cyclone feed chute.
from cyclones
Loss of body parts,
Scaffolding may Cross check the scaffolding as per the standard. Hazards to
Injury leading to
collapse. be explain to the workers through tool box talk before
permanent disability, 5 2 10
Scaffolding pipe starting the job.
Loss of body parts,
may slip
Coating may Injury leading to Check the coating thickness, how strong it is. if it is weak,
collapse inside the permanent disability, 5 2 10 remove the coating and check the kiln.
kiln Loss of body parts,
Ignition of Use of PPE (Hand Gloves & Googles),Deploy trained person
Injury requiring First Aid. 2 2 4
flammables and space made free of flammable
Injury requiring Restrict person movement by barricading. Use of safety nets,
Fall of person hospitalization, Eye injury - 5 2 10
& Scald.
Injury requiring Tool box talk for material handling,
Removal of Old Fall of debris hospitalization, Eye injury - 5 2 10
Damaged Lining & Scald.
and Castable Injury requiring Allot trained workers, Conduct TBT before stating the job.
Slip/fall of material
(Preheater) hospitalization, Eye injury - 5 2 10 Restrict person movement by barricading. Use of safety nets,
or man.
& Scald.
Injury requiring Ensure PPE usage & ensure dust free environment.
Inhalation of dust hospitalization, Eye injury - 3 3 9
& Scald.


Injury requiring Inspect the area, Hazards to be explained to the workers
Caught between,
hospitalization, Eye injury - 5 2 10 through PEP talk.
snake bite
& Scald.
Use only load tested lifting equipment. Cross check the rope,
Refractory Injury requiring cage condition with check lists. Hoist operator is to be
Fall of material,
material& hospitalization, Eye injury - 5 2 10 authorized.
hoist failure
Scaffolding pipes & Scald.
shifting from
yard to work Rope may failure or Injury requiring Change the rope timely as per the suppliers guarantee. Use
place improper position hospitalization, Eye injury - 5 2 10 skilled man power for shifting the pallets.
of rope & Scald.
Injury requiring Hazards to be explain to the workers through PEP talk (Nylon
Scaffolding pipe,
hospitalization, Eye injury - 4 2 8 rope failure, pipe may slip if it is improper tightening)
clamp, grit may slip
& Scald.
Injury requiring Allot trained workers, SOP to be followed.
hospitalization, Eye injury - 5 3 15
or man.
& Scald.
Brick lining in Kiln
Brick fall down may Injury requiring Walkway should not be block while brick transporting
hit the person who hospitalization, Eye injury - 5 3 15 happen. Avoid working below the walkway/ net to be
is standing nearby. & Scald. provided. Skilled person to be deployed on job.
Injury requiring Use appropriate PPE's. Person should stand away in front of
Fine Coal bin Splash /spills of
hospitalization, Eye injury - 4 3 12 the door.
Cleaning materials
& Scald.
Injury leading to Co2 purging interlock with high Temperature /CO-0.15%.
Coal Grinding Fire permanent disability, - 5 2 10 Monitoring from CCR along with explosion vents. Avoid the
Loss of body parts, Burns. entering of excess O2 by false air.


Injury leading to CO2 purging interlock with high Temperature /CO- 0.15%.
Coal Grinding Explosion permanent disability, - 5 2 10 Monitoring from CCR along with explosion vents. Avoid the
Loss of body parts, Burns. entering of excess O2 by false air.
Lifting of Use only load tested lifting equipment. Cross check the rope,
refractory & Injury requiring cage condition with check lists. Hydra operator is to be
Falling of Material /
other materials hospitalization, Eye injury - 4 2 8 authorized.
Cage
to the heights by & Scald.
hydra
Injury leading to Thorough inspection of the diesel line before starting the
Fire or explosion
Permanent disability, - 5 2 10 pump.
(Diesel may leak )
Injury leading to Check the diesel pipe condition periodically as per supplier
Body Injury (Diesel
Permanent disability, - 5 2 10 recommendation.
pipe may burst)
Injury leading to Close all air blasters vent out the residual air if any. System
Splash /spills of
Permanent disability, - 5 2 10 (kiln) air to be vent by fresh air damper.
diesel in system
Kiln Firing with Loss of body parts, Burns
Diesel Injury leading to Use fire proof glass and fire proof face shield. Maintain
Back Fire Permanent disability, - 5 2 10 appropriate draft in system.
Injury leading to Control on coal feed. Maintain appropriate draught in
Fire Permanent disability, - 5 2 10 system.
Injury leading to Online gas analyzers ( Kiln inlet, PC inlet & PH outlet) &
Splash of gases Permanent disability, - 4 2 8 draught control
Hand trap between Use appropriate PPE (Hand Gloves & Googles), Deploy
Injury requiring First Aid. - 4 2 8
blade & table trained person.


Use appropriate PPE (Hand Gloves & Googles), Deploy
Refractory Mixer Electrocution Injury requiring First Aid. - 4 2 8
trained person
machine Cleaning
Castable bag may Use appropriate PPE (Hand Gloves & Googles), Deploy
& Operation Injury requiring First Aid. - 2 2 4
slip trained person
Slip/fall of socket, Injury requiring Conduct Tool box talks before performing the job. Allot the
- 3 2 6
bolt Or spanners. hospitalization, Eye injury trained workmen with appropriate PPEs.
Slip/fall of Conduct Tool box talks before performing the job. Allot the
Injury requiring
measuring - 3 2 6 trained workmen with appropriate PPEs.
hospitalization, Eye injury
equipment’s
May be touch the Conduct Tool box talks before performing the job. Allot the
Flow Injury requiring
thermometer - 4 2 8 trained workmen with appropriate PPEs.
Measurement hospitalization, Eye injury
needle
Conduct Tool box talks before performing the job. Allot the
Injury requiring
Sudden release of - 5 2 10 trained workmen with appropriate PPEs. Inform to CCR to
hospitalization, Eye injury
Gas & materials maintain the draught.
Slip/fall of socket, Injury requiring Conduct Tool box talks before performing the job. Allot the
- 5 2 10
bolt Or spanners. hospitalization, Eye injury trained workmen with appropriate PPEs.
Degree of Injury leading to Use appropriate PPE's & trained person to be deployed.
Splash of Hot
calcination Permanent disability, - 3 2 6
material
sample collection Loss of body parts, Burns
Fire proof glass to be used., Use appropriate PPE's & maintain
Injury leading to
Inspection of Kiln Splash of Hot proper hood draught.
Permanent disability, - 3 2 6
Flame condition material
Injury leading to Use appropriate PPE's (Face shield & fire proximity suit).
Removal of Flush / Emission of
Permanent disability, - 3 2 6 Maintain proper draught.
coating at kiln hot material


inlet & burner
pipe
Material may be Conduct Tool box talks before performing the job. Allot the
puffing back side trained workmen with appropriate PPEs.
Conduct Tool box talks before performing the job. Allot the
Hand irritation Injury requiring First Aid. - 2 2 4
trained workmen with appropriate PPEs.
False air arresting Puffing of hot air or Conduct Tool box talks before performing the job. Allot the
material, May trained workmen with appropriate PPEs.
material or hot Injury requiring First Aid. - 2 2 4
gasses splash on
body
Injury requiring Restrict person movement by barricading, Use of safety nets,
Fall of person hospitalization, Eye injury - 5 2 10 Ensure PPE usage & ensure dust free environment,
& Scald. SOP/PRO/011
Fall of Refractory Tool box talk for material handling,
material
Injury requiring Tool box talk for material handling
Lining of Slip/fall of debris hospitalization, Eye injury - 5 2 10
Refractory in PH & Scald.
Injury requiring Tool box talk for material handling, Dummy to made and
Slip/fall of material. hospitalization, Eye injury - 5 2 10 Safety net should be use on top of the work place, Jallies also
& Scald. to be use on top of work place.
Injury requiring Ensure PPE usage & ensure dust free environment. Allot
hospitalization, Eye injury - 5 2 10 trained workers
or man.
& Scald.

PROBABILITY/LIKELIHOOD OF OCCURRENCE: IMPACT SEVERITY RATINGS: CONSIDERATION DURING THE REVIEW:

1. UNLIKELY may not occur 1 - Insignificant; Negligible N - Normal Condition
2. SELDOM, unlikely but possible to occur (yearly) 2 - Minor, Minimal health & safety effect (minor A - Abnormal Condition
effect on human health/first-aid needed)
3. OCCASIONAL, likely to occur sometimes (monthly) 3 - Moderate, minor health & safety effect E - Emergency Condition
4. LIKELY, will occur several times (weekly) 4 - Critical, minor health & safety effect that cannot -
be
5. FREQUENTLY, likely to occur always (Daily) 5 - Catastrophic, major health & safety effect that -
cannot be controlled. (Likely to result in severe
injury or ill health & fatality).

Expansion of Integrated Cement Plant - Clinker (4.0 to 8.0 MTPA), Cement (4.0 to 8.0 MTPA) and WHRS (16 MW to 32 MW)
At Village - Mohanpura, Tehsil – Kotputli, District -Jaipur (Rajasthan)
Risk Assessment Report
1.3.4 Disaster Management Plan
Definition
A major emergency in a work 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 work.
It would require the assistance of emergency services to handle it in effective manner.
Scope
The aim of hazard control and disaster management is concerned with preventing accidents
through good design, operation, maintenance and inspection, by which it is possible to reduce the
risk of an accident, but it is not possible to eliminate it. Since, absolute safety is not achievable; an
essential part of major hazard control must also include mitigating the effects of a major accident.
An important aspect of mitigation is emergency planning, i.e., identifying accidents as soon as
possible, evaluating the consequences of such accidents and deciding on the emergency
procedures, both on-site and off-site, that would need to be adapted in the event of an emergency.
Objective
The objectives of the emergency plan will be:
a) To protect plant personnel and general public.
b) To prevent and minimize damage to property and to the environment.
c) To help persons at site in a systematic manner meeting a disaster situation.
d) To restore the affected areas back to normal as soon as possible.
e) To review accident after it has occurred and to evaluate company’s efforts in order to improve
emergency management response in the future.
To deal with the below emergencies, the Emergency Plan is prepared.

S. No. Area Possible Emergency Hazard Preventive Measures to be adopted
a) Stores Possibility of catching Fire • Suitable fire extinguishers, fire hydrant system
fire in stores materials and fire buckets will be provided for fighting the
fire during emergency.
• Stores staff will be imparted the training for
first aid firefighting to prevent/extinguish the
fire at initial stage.
b) Oil Storage Possibility of catching Fire and • Fire hazard area will be declared as “No
Tank - HSD fire at the oil storage Explosion Smoking and No Naked Flame Zone” and
Tank tanks and fuel oil regular check- up and maintenance of the fire
handling system and prone area will be done.
Oil spillage from • Suitable fire extinguishers and fire hydrant
storage tanks system will be provided at the tank enclosure
and inside the pump room.
• Unloading of petroleum in bulk will not be
allowed between sunset and sunrise. Tanker
engine will be switched off before unloading
and the tanker will be earthed.


• Regular scheduled inspections of storage tank
and the enclosed area will be carried out by the
custodian with regard to proper earthling,
presence of any combustible material or
growth of wild vegetation, no breaches in the
wire fencing, damage in the dyke wall etc.
c) Packing Possibility of catching Fire • The packing plant will be declared as “No
Plant fire in the bag Smoking of Fire” area.
godown • Suitable fire extinguishers and fire hydrant
systems will be provided for firefighting in
emergency situation.
• Permission will be taken for working with
welding/gas cutting in that area.
• Adequate drainage to immediately drain out
the water used in firefighting will be provided
to avoid water damage and the sheds will be
properly ventilated.
• The sheds will be properly ventilated.
d) Silos Collapse of silos Physical • Structural Soundness of silos will be ensured
resulting in dust and filling up of Silos will be avoided.
emission, material • Avoid over filing of silos
spillage & injury to • Lighting arrestor at top of silos bucket elevator
person & damage to will be installed.
other property
e) Storage of Catching fire due to Fire • Flammable, ignitable, reactive and non-
AFR & Coal material spillage compatible wastes will be stored separately
leading to damage to and will never be stored in the same storage
property shed
• Adequate storage capacity will be provided in
the premises.
• Storage area will be designed to withstand the
load of material stocked and any damage from
the material spillage.
• Automatic smoke, heat detection system will
be provided in the sheds.
• Adequate fire-fighting systems will be provided
for the storage area, along with the areas in the
facility.
• Coal will be stored in covered shed.
f) Electrical Catching fire in Fire and • Predictive interlocks will be provided which will
Transformer transformers Explosion automatically give an alarm/trip the system.
• In case oil pressure inside the transformer tank
increases, buchholtz relay provided will sound
an alarm and if necessary, will trip the
transformer and thus avoid oil explosion.


• A diaphragm will be provided at the bottom of
explosion vent to vent out high oil pressure
whenever pressure is increased beyond limit.
g) Transformer Possibility of fire and Fire and • Transformers will be separated by brick wall up
Yard and explosion Explosion to height of transformer.
HT/LT Sub- • Soak pits of suitable capacity will be provided to
Station collect the leaked transformer oil in case of fire
and explosion.
• Periodic maintenance of all electrical machinery
apparatus will be done.
• In case of fire in HT transformer, first of all
switch off 33/132 kV Incomer breaker
• In case of LT transformer fire/explosion, switch
off the transformer feeder from HT line
• Emergency control room will be informed for
fire brigade and other actions
h) Electrical Catching fire in Fire • Suitable fire extinguishers will be provided for
Cable electrical cables inside firefighting.
Tunnels the tunnels • Good housekeeping will be ensured to avoid
any fire rise.
• Exhaust fans will be provided to avoid
suffocation.
i) Conveyor Catching of fire in Fire • Suitable Fire extinguishers will be provided for
Belts conveyors due to Gas each transfer towers for firefighting during
cutting / welding emergency
and Frictional heat • Suitable fire equipment will be kept at hand
during gas cutting / welding.
• Full cord system will be provided throughout its
length to stop it in any emergency
• Preventive checks on frictional parts like drum
and lagging of drum will be done.
j) Failure of Injury to person and Physical • All lifting tools and tackles and pressure vessels
Lifting Tools damage to equipment will be tested/examined by competent person
and Tackles authorized by chief inspector of factories, Govt.
and of Rajasthan as per statutory requirement and
Pressure at defined frequency
Vessels • Safe working pressure range will be maintained
in the Air receiver tank/pressure vessels
• Safe Working Load will not be violated while
using cranes, hoists, ropes, chains and other
lifting tools and tackles, only authorized
personnel will be allowed to handle the same
• Regular and periodic maintenance will be done.


k) Oil Tankers Toppling of Oil Physical • Speed limit signboards will be displayed; no
Tankers vehicle will be allowed to move beyond 20
km/hr
• In case oil is toppled, Plant Inventory
department will be informed
• Sand will be sprayed on the oil to prevent
further spread of oil and oil-soaked sand will be
collected to fill in the land and cover with soil
l) Working at Fall from Height Physical • Information will be given immediately to
Height resulting in injury to Emergency Control Room/ OHC and to the Job
person Execution In-charge
• Rescue team member will rush at site with
rescue kit
• Emergency team will be allotted to act as per
Emergency organization structure
• Rescuers to access the probable risk for
rescuing the victim
m) Stockpiles Engulfment in Physical • Take permission before climbing on stock pile
Stockpile • Pedestrian to maintain a safe distance from
stock pile
• Person to work under close supervision
• In case of Emergency, inform immediately to
Emergency Control Room/OHC and to the Job
Execution In-charge
n) ESP Release of Particulate Events • All the stack will be equipped with Continuous
matter in case of Pertaining to Online Monitoring Systems and connected with
failure of chambers of Manufacturing Central Control Room in the plant for
ESP or tripping of ESP Process monitoring the emissions.
• All the arrangements will be done to avoid
tripping in the ESP along with interlocking
system.
• Proper maintenance of Air Pollution Control
Equipment will be done periodically.
1.3.5 Onsite Emergency Plan
1.3.5.1 Onsite Emergency Plan

The Onsite Emergency Management Plan is a master plan which contains the emergency
organization structure, responsibilities of key members, communications mean and emergency
response strategies to control a range of major incidents.
 Risk Scenarios at Prism Cement Limited

Potential and high hazard situation will be treated as major emergency. Emergency will be declared
by the Head-EHS after assessing the situation.

The prime risk scenarios as evaluated from hazard identification are:

Fires: Fire at fuel storage yard, Trash catching fire, diesel fire, cable fire, Paint fires, construction
waste fires, electrical fire in panels, transformer oil fire, Fire in administrative building, combustible
gas fire, and flammable liquid fire, etc.
Explosion: LPG cylinder explosion, air receiver cylinder bursting, bomb explosion, gas pipe line
bursting, bursting of new fuel pipe line during testing, etc.
Leakage: Leakages of toxic gases, combustible gases etc.
Spillage: spillages of acids / chemicals / flammable liquids/ non-flammable liquids etc.
Contamination: Drinking water contamination with poisonous chemicals.
Construction disasters: Building collapse, form work collapse, rubbish chute choke, scaffolding
collapse, tower crane collapse, mobile crane/crawler crane topple, Major electrical shutdown
(during night time)
Road emergencies: Road accidents
Others: Cyclonic winds, Flooding, Food poisoning, epidemics, earth quake, Landslides etc.
 Emergency Organization and its Responsibilities
Works Main Controller

(Unit Head)
Coordinator (SAFETY)
Site Incident Controller (SIC)

(Process Head / Engg. Head)
Auxiliary Team Leader (ATL) Combat Team Leader (CTL) Rescue Team Leader (RTL)
(Personnel / HR/ PR) (Operation / Maintenance) (Medical Fire and Security)
Members Members Members
Figure 2: Emergency Command Structure

Responsibilities and Duties of Personnel
Designated roles of Emergency

S. No. Responsibilities
Command Structure
1. Works Main Controller • Relieve the site incident controller of responsibility for overall
control.
• Ensure that the outside emergency services are called in.
• Ensure that key personnel are called in.
• Exercise direct operational control of those parts of the work outside
the affected area.
• Maintain a speculative continuous review of possible developments
and assess these to determine most probable course of events.
• Direct the shutting down of equipment and evacuation of areas in
consultation with the site incident controller and key personnel.
• Ensure the casualties and receiving adequate attention. Arrange for
additional help, if required. Ensure that relatives are advised.
• Liaise with Chief Officers of the fire and police services and with the
experts on fire, safety, health etc. provide advice on possible effects
on areas outside works.
• Where the emergency is prolonged, arrange for the relief of
personnel and the provisions of catering facilities.
• Ensure the proper consideration is given to the preservation of
evidences for investigations
• Ensure with site incident controller about instructions of “ALL
CLEAR” communication.
• Ensure and control rehabilitation of affected areas.
• Communication to Prism Johnson Limited followed by a written
report about the accident, including mitigation action taken.
2. Site Incident Controller (SIC) • Assess the scale of emergency and decide if a major emergency
situation exists or is likely. On this decision, he will activate the
subsequent major emergency procedure.
• Direct all operations within the affected area with the following
priorities:
• Secure the safety of personnel
• Minimize damage to equipment, property and the environment
• Minimize loss of material
• Direct rescue and firefighting operations
• Ensure that the affected area is searched for unattended casualties.
• Ensure that all non-essential workers in the affected area evacuate
to the appropriate assembly point.
• Direct the outside emergency services if called for emergency.
• Pending the arrival of the site main controller, assume the duties of
the post and, in particular:
 Direct the shutting down of equipment and evaluation of areas
likely endangered by the emergency.
 Ensure that the outside emergency services have been called
in.


Command Structure
 Ensure that key personnel have been called in.
• Report all significant development to the site main controller.
Provide advice and information, as required, to the senior officer of
the Fire Brigade.
• Ensure the head counting for personnel.
• Control traffic movement within the works.
• Ensure that chronological record of the emergency to be maintained.
• Have regard to the need to preserve evidence that would facilitate
any subsequent esquire into the cause and circumstances of the
emergency.
• Direct the instructions about the “ALL CLEAR” communication
through mobile phones & walkie-talkie
3. HR & ADMIN – Head • He handles the evacuation of the personnel from the emergency
situation to the Assembly point.
• He takes the head count of the Evacuated personnel.
• He will assist the site controller in liaise with the local emergency
authorities.
• Manage traffic movement towards the incident area and clears way
to the Emergency vehicles.
4. Electrical – Head • He will be the heading the Shutdown.

• After receiving the communication from the Incident controller, he
will arrange to stop the power supply to the site and shutdown of the
other equipment at site as per requirement.
• After receiving the “All Clear” communication from the incident
controller, he will resume the power supply to site.
5. Mechanical – Head • He will be the heading the heavy equipment
• After receiving the communication from the Incident controller, he
will arrange to properly access at site.
• After receiving the “All Clear” communication from the incident
controller, he will resume the tool tackles (welding machine, cutting
machine, grinding machine etc.) to site.
6. Fire Fighting Team • After receiving the emergency communication, they will immediately
report to the Incident controller.
• As per his instruction they will mobilize the Firefighting equipment’s
and Leak control kits etc.
• They will control the fire & Gas leakages.
• In emergency situation other than Fire & Gas leakages, they will help
the first aid team.
7. First Aid Team • After receiving the emergency communication First aid team will
immediately report to the Incident controller
• First aid team will remove the causalities from the incident area to
the safe place.
• They will provide the immediate first aid to the casualties.


Command Structure
• Help them to transport to the medical aid if warrants.
8. Area in-charge of Emergency • He will immediately proceed to the scene of incident to confirm and
Affected Area assess the situation.
• He will notify the nature of emergency to the fire station and security
office to inform SIC / SMC and the concerned persons.
• Area In-charge should clearly indicate to fire station and security
office about
I) Nature of emergency
II) Location of emergency
• He will ensure that all hot jobs including welding, cutting, grinding,
chipping, open fire heating, etc. are stopped in the area.
• He will coordinate the actions of site emergency services,
maintenance services and other services for quick control of the
situation, he will also perform emergency control measures as per
directions from SIC / SMC.
• He will furnish the full details about the incident to the Senior
Management and Safety Officer, SMC / SIC, and other emergency
services at site.
• He will set up an emergency control post on site for team leaders of
assistance groups from where the control and direction of the
emergency operation is safe and he will arrange some
communication media e.g. telephone at the emergency control post.
• He will keep himself in constant touch with the emergency post and
continue to pass on information / receive direction from emergency
post to the concerned personnel.
• He will ask for spare manpower from the other area in-charges of the
unaffected area.
Emergency organization during non-working hours

The help of most of the personnel listed earlier will not be available and hence a separate working
procedure has to be followed:
 All applicable duties for silent hours / enumerated earlier will apply.
 In-charge of the affected area will handle the situation with the available manpower and
services, till the designated authorities of emergency organization reach the emergency site.
Acting Site Main Controller

Area In-charge
Shift In-charge (SHE) Shift In charge (Med.) & Shift In charge (Security) &
Shift Staff Shift Staff Shift Staff

 Emergency Control Post

Emergency control post will be set up at the time of any major emergency, by the in-charge of the
concerned area, for team leaders of assistance groups, from where the control and directions of
the emergency operation is safe. Communication media e.g., telephone will also be provided at the
control post.
 Assembly Points
The assembly points will be provided so as to cover the whole site area with the consideration of
wind direction, nearby paging facility and more than one road approach on each point.
 Alarm System
Alarm systems vary and will depend on the size of the plant. There should be an adequate number
of points from an audible warning, or indirectly, viz. a signal or message to a permanently manned
location. There should be a reliable system for informing the emergency services as soon as the
alarm is raised on site.
 Communication System
Communication is crucial factor in handling an emergency. It is the practice at many plants that any
employee can raise an emergency alarm, so allowing the earliest possible action to be taken to
control the situation. The possible communication can be given by telephone, shouting, messenger
and walkie-talkie.
Concerned SHE In-charge will inform the Fire Station through the quickest way possible for quick
response and Security Office for passing of the information to the concerned persons and services.
The following persons and services inside the work place will be informed in case of major
emergencies like – major fire, major accident, major spillage, gas leak, cyclone, etc. These
authorities and services will be notified by Security Officer as per the direction by the Head - SHE of
the Site. Fire Station, Medical Centre / Medical In-charge, Plant head, SHE Staff and Security Staff.
(i) Fire-fighting System
In view of vulnerability to fire, effective measures will be taken to minimize fire hazard. Fire
protection is envisaged through hydrant and sprinkler system, designed as per the
recommendation of Tariff Advisory Committee of Insurance Association of India. The following
areas in the power station are mainly susceptible to fire:
 Cable galleries
 Electrical switchgear/ MCC room
 Coal handling areas: Conveyors, transfer points, tunnels and storage yard.
 Transformers and turbine oil tank
For detection and protection of the plant against fire hazard, any one or a combination of the
following systems will protect susceptible areas:
 Hydrant system.
 Automatic high velocity spray system
 Medium velocity spray system

 Portable fire extinguishers

 Fire alarm systems
Fire hydrant points will be provided throughout the premises. Automatic high velocity spray system
will be provided for protection of transformers and cable galleries. Manual medium velocity spray
system will be provided for protection of fuel oil and turbine oil storage tanks and coal conveyor
galleries.
Water for hydrant, spray and sprinkler system will be supplied from the firewater pumps located in
firewater pump house adjacent to Raw Water Reservoir. Adequate number of portable and mobile
chemical fire extinguishers will be provided at strategic locations throughout the plant. Fire
detection and alarm system will be provided at strategic locations throughout the plant. Fire
detection and alarm system will be provided to detect fire/ smoke in vulnerable areas of the plant
through smoke /heat detectors. Table - 3 and Table - 4 enlist case and Site-Specific Fire extinguishers
respectively.
Table - 3
List of Extinguishers to be used as case specific
S. No. Chemical Name Type of Extinguisher to be used
1. Coke Water fog, CO2, Foam, Dry Chemical
Water spray, foam, dry powder or carbon dioxide
2. Fuel Oil Do Not Use: water jet as an extinguisher, as this will spread
the fire
Foam, Carbon dioxide, Dry Chemical Powder. Water may
3. HSD
be used to cool fire-exposed containers
water fog, foam, dry chemical or carbon dioxide (CO2) to
4. LDO
extinguish flames
5. Fly Ash Non- Flammable
6. Gypsum Non- Flammable
7. Laterite / Iron Ore Non- Flammable
8. Metal dust Certified class D Extinguishing agent
Table - 4
List of Extinguishers to be used as Site specific
S. No. Name of site Type of Extinguisher

1. Cable galleries CO2 and Foam type, Dry chemical powder
2. High voltage panel CO2 and Foam type, Dry chemical powder
3. Control rooms CO2 and Foam type, Dry chemical powder
4. MCC rooms CO2 and Foam type, Dry chemical powder
5. Pump Houses CO2 and Foam type, Dry chemical powder
6. Guest houses and offices Dry chemical powder, foam type
7. Godowns Foam type
Bunkers, Silo, enclosed dust CO2 type, N2 type, automatic sprinkler, fixed spray nozzle
8.
collector (unless water reactive)

 Emergency Evacuation Procedure

 On receipt of evacuation instructions, the personnel in the affected area shall proceed to
their designated assembly point.
 On receipt of evacuation, personnel shall close all the working gadgets, taking care that
closing or shutting down operations does not lead to additional hazards.
 When the emergency is announced, one security guard at the site gate will be posted by
security section and he will secure the vehicle gates halting all routine traffic and material
movement into the site. This guard shall clear the road from the main gate so that if outside
emergency vehicles are needed the road be clear.
 All personnel of the site will remain at their announced assembly points until the clear signal
is announced.
 When the emergency announcement has been made, outside contractors on site will be
instructed to report to the gate. Their supervisors should make a count of all personnel and
report this data to the security at the gate.
 Evacuation of the people will be especially in the opposite direction of exposure / wind
direction.
S. No. Emergency Mitigation Measures
1. Fire In case of emergency, if required, help would be taken from nearby city
fire station and industries under mutual aid arrangement, in addition to
our own firefighting systems as fixed installations and other firefighting
equipment’s.
2. Collapse of Building, Shed or • In case of Collapse of Building, Shed or structure, and emergency alarm
Structure will be raised, all the Head - SHE will be informed and area will be
evacuated.
• Fire Brigade will be called to assist the removal debris from site and all
medical help will be arranged immediately.
3. Liquid Spill • The spillage will be localized and cordoned off immediately.
• Vehicular traffic will be stopped by the security staff in the affected area
of plant.
4. Storm • Removal of all loose, light objects, buckets, ladders, maintenance
material etc. from the site will be ensured.
• Hydra, trucks, welding machines, etc. will be placed at safe
positions/places and the material that can’t be moved to a safe location,
will be lashed in place in the best possible manner known.
5. Riot or Civil Disturbances • Information will be given to SH (P&A) / SH (Security) regarding the
Procedure or Bomb Threat suspected person/activity.
or Terrorist Attack • On duty staff or other personnel assigned under emergency notification
of company will be immediately called for alertness.
• All the site entry gates will be locked and entry of any unauthorized
person to the plant site will be prohibited.
• Emergency vehicles, medical staff, first aid and safety staff and All area
in-charge will be kept alerted / ready.

 First Aid
A first aid center with adequate facilities will be provided. It will be maintained round the clock by a
compounder cum dresser and a doctor. An auxiliary first aid squad will be identified, the members
of which will be spread in each shift in different departments. In the event of an emergency this
squad will augment medical services. An Ambulance which will be available with plant will also be
used at site to carry affected people to hospital. Assistance of these hospitals will be taken in case
of any necessity.
 Safety
The safety wing led by a Safety officer will meet the requirement of emergencies round the clock.
The required safety appliances will 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.
 Emergency Drills
The emergency response plans and emergency preparedness level would be tested through the
following drills:
a. Table-top exercise (TTE)
b. Functional exercise (FE)
c. Full-scale exercise (FSE)
All elements/procedures of the On-Site Emergency Plan would be first tested through TTE and
perfected to the extent possible. The Plan then would be modified/ updated. Functional Exercises
basically to ensure proper functioning of various equipment such as the fire-fighting equipment and
the fire hydrant system. The Full-Scale Drill would be conducted to know the level of preparedness
of all teams. Initially, TTE and FE would be conducted periodically.
The following drills will be conducted periodically:
a. Plant Emergency Drill for fire
b. Fire Drills at offices and admin building
c. Plant Emergency Drills (fire scenario involving evacuation)
 Personal Protective Equipment (PPEs)

Personal protective equipment plays a vital role in overcoming major disastrous situation saving life
during onsite emergency. List of recommended Personal Protective equipment (PPE) is given below
in Table - 5.
Table - 5
Summary of Recommended Personal Protective Equipment according to hazard onsite
Objective Workplace Hazards Suggested PPE
Eye and face Flying particles, molten metal, liquid Safety glasses with side-shields, protective shades,
protection chemicals, gases or vapors, light etc.
radiation
Head protection Falling objects, inadequate height Plastic helmets with top and side impact protection
clearance, and overhead power cords
Hearing protection Noise, ultra-sound Hearing protectors (ear plugs or ear muffs)

Objective Workplace Hazards Suggested PPE

Foot protection Failing or rolling objects, points Safety shoes and boots for protection against moving
objects. Corrosive or hot liquids and failing objects, liquids and chemicals
Hand protection Hazardous materials, cuts or Gloves made of rubber or synthetic material
lacerations, vibrations, extreme (Neoprene), leather, steel, insulation materials, etc.
temperatures
Respiratory Dust, fogs, fumes, mists, gases, Facemasks with appropriate filters for dust removal
protection smokes, vapors and air purification (chemical, mists, vapors and
gases). Single or multi-gas personal monitors, if
available
Oxygen deficiency Portable or supplied air (fixed lines).
Onsite rescue equipment
Body / leg Extreme temperatures, hazardous Insulating clothing, body suits, aprons etc. of
protection materials, biological agents, cutting appropriate materials
and laceration
Fly Ash Fly ash handling and storage Wear dust-proof goggles and rubber or PVC gloves.
When using large quantities or where heavy
contamination is likely, wear: coveralls.
Apart from this, all the employees will be provided with helmets and safety shoes. It will be
statutory on the part of the company employees to wear the appropriate safety gear given while
attending duty in the factory.
1.3.5.2 Off-Site Emergency Planning
The off-site emergency plan is vital part of any hazard control system. It is based on those accidents
identified by the works management, which could affect people and the environment outside the
works. Thus, the off-site plan follows logically from the analysis that took place to provide the basis
for the on-site plan and the two plans therefore complement each other. The roles of the various
parties that may be involved in the implementation of an off-site plan are described below. The
responsibility for the off-site plan will be likely to rest either with the works management or with
the local authority. The plan must identify an emergency coordinating officer who would take
overall command of the off-site activities. Consideration of evacuation may include the following
factors:
 In the case of a major fire but without explosion risk (e.g. an oil storage tank), houses close to
the fire are likely to need evacuation
 If fire is escalating very fast it is necessary to evacuate people nearby as soon as possible.
 In acute emergency people are advised to stay indoors and shield themselves from the fire.
Organization
Organizational details of command structure, warning systems, implementation procedures,
emergency control centres include name and appointments of incident controller, site main
controller, their deputies and other key personnel involved during emergency.

Communications
Identification of personnel involved, communication centre, call signs, network, list of telephone
numbers.
Special Emergency Equipment

Details of availability and location of heavy lifting gear, specified fire-fighting equipment, fireboats
etc.
Voluntary Organizations
Details of Voluntary organizations, telephone numbers nearby hospitals, Emergency helpline,
resources etc. are to be available with chief authorities.
Non-government Organizations (NGO)

NGOs could provide a valuable source of expertise and information to support emergency response
efforts. Members of NGOs could assist response personnel by performing specified tasks, as
planned during the emergency planning process.
 Evacuation of personnel from the affected area
 Arrangements at rallying posts and parking yards
 Rehabilitation of evacuated persons
Chemical information
Details of the hazardous substances (MSDS information) and a summary of the risks associated with
them are to be made available at respective site.
Meteorological information
There is to be arrangements for obtaining details of weather conditions prevailing at before the
time of accident and weather forecasts updates.
Humanitarian Arrangements
Transport, evacuation centres, emergency feeding, treatment of injured, first aid, ambulances,
temporary mortuaries.
Public Information
 Dealing with the media-press office
 Informing relatives, etc.
Assessment
 Collecting information on the causes of the emergency
 Reviewing the efficiency and effectiveness of all aspects of the emergency plan.
Role of local authority
Local Authorities like Panchayat, Sabha, Samiti, municipalities can help in combating emergency
situation after assessing the impact scenario in rescue phase.
Role of police
 Concerned police will be available for controlling and guidance at the accident site,
organizing evacuation and removing of any seriously injured people to hospitals.
 Co-ordination with the transport authorities, civil defence and home guards

 Co-ordination with army, navy, air force and state fire services
 Arrange for post mortem of dead bodies
 Establish communication centre with easy contact with ECC
Role of Fire Brigade

The fire brigade is to be organized to put out fires and provide assistance as required during
emergency.
Media
 The media is to have ready and continuous access to designated officials with relevant
information, as well as to other sources in order to provide essential and accurate
information to public throughout the emergency and to avoid commotion and confusion.
 Efforts are made to check the clarity and reliability of information as it becomes available,
and before it is communicated to public.
 Public health authorities are consulted when issuing statements to the media concerning
health aspects of chemical accidents.
 Members of the media are to facilitate response efforts by providing means for informing
the public with credible information about accidents involving hazardous substances.
Role of health care authorities
 Hospitals and doctors must be ready to treat all types of injuries to causalities during
emergency
 Co-ordinate the activities of Primary Health Centres and Municipal Dispensaries & District
Hospital to ensure required quantities of drugs and equipment.
 Securing assistance of medical and paramedical personnel from nearby
hospitals/institutions.
 Temporary mortuary and identification of dead bodies.
1.3.1 Conclusion
It has concluded that there will be no major risk involved due to Proposed Integrated Cement
Project. Suitable Risk Control Measures with respect to Risk Assessment will be implemented to
minimize the risk to an acceptable level. Regular Training, Implementation of SOPs and compliance
of relevant Personal Protective Equipment’s (PPEs) will help to minimize the health hazards and
incidental casualties. So, it is safe to say that there will be no major risk involved due to the
proposed project.

Fauregzlusm 14320326 Risk Assessment Report

Uploaded by

Document Information

Original Description:

Original Title

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

Fauregzlusm 14320326 Risk Assessment Report

Uploaded by

Copyright:

Available Formats

RISK ASSESSMENT REPORT

Proposed Integrated Cement Project - Clinker (3.0

M/s. PRISM JOHNSON LIMITED

RISK ASSESSMENT REPORT

1.1 RISK ASSESSMENT AND DISASTER MANAGEMENT PLAN

Figure: 1: Risk Analysis Strategy

M/s. Prism Johnson Limited 1

Department / Location Activity Hazards / Impact

M/s. Prism Johnson Limited 2

S. No. Possible Hazard Cause of Hazard Safety Measures

M/s. Prism Johnson Limited 3

S. No. Possible Hazard Cause of Hazard Safety Measures

1.3.1 Natural and Manmade Calamities which can lead to Emergency

S. No. Calamity / Activity Mitigation Measures

M/s. Prism Johnson Limited 4

S. No. Calamity / Activity Mitigation Measures

Hazard Identification & Risk Assessment (HIRA) - Cement Manufacturing process -

M/s. Prism Johnson Limited 5

Activity/Products Locati Severity Probability of Risk

M/s. Prism Johnson Limited 6

Activity/Products Locati Severity Probability of Risk

M/s. Prism Johnson Limited 7

Activity/Products Locati Severity Probability of Risk

M/s. Prism Johnson Limited 8

Activity/Products Locati Severity Probability of Risk

M/s. Prism Johnson Limited 9

Activity/Products Locati Severity Probability of Risk

M/s. Prism Johnson Limited 10

Activity/Products Locati Severity Probability of Risk

M/s. Prism Johnson Limited 11

Activity/Products Locati Severity Probability of Risk

M/s. Prism Johnson Limited 12

PROBABILITY/LIKELIHOOD OF OCCURRENCE: IMPACT SEVERITY RATINGS: CONSIDERATION DURING THE REVIEW:

M/s. Prism Johnson Limited 13

1.3.4 Disaster Management Plan

To deal with the below emergencies, the Emergency Plan is prepared.

M/s. Prism Johnson Limited 14

S. No. Area Possible Emergency Hazard Preventive Measures to be adopted

M/s. Prism Johnson Limited 15

S. No. Area Possible Emergency Hazard Preventive Measures to be adopted

M/s. Prism Johnson Limited 16

S. No. Area Possible Emergency Hazard Preventive Measures to be adopted

1.3.5 Onsite Emergency Plan

1.3.5.1 Onsite Emergency Plan

 Risk Scenarios at Prism Cement Limited

M/s. Prism Johnson Limited 17

The prime risk scenarios as evaluated from hazard identification are:

 Emergency Organization and its Responsibilities

Works Main Controller

Site Incident Controller (SIC)

Members Members Members

Figure 2: Emergency Command Structure

M/s. Prism Johnson Limited 18

Responsibilities and Duties of Personnel

Designated roles of Emergency

M/s. Prism Johnson Limited 19

Designated roles of Emergency

4. Electrical – Head • He will be the heading the Shutdown.

M/s. Prism Johnson Limited 20

Designated roles of Emergency

Emergency organization during non-working hours

Acting Site Main Controller