.

Risk Assessment:
Hazard identification and control has been suggested to visualize all
conceivable deviations from the intended plant and which could be a source of
potential hazard to the people, plant, product and environment, and thereby to
take remedial action by analyzing the causes and consequences. Since it is an
existing project On site & Off site emergency plan & Disaster management plan
are already in place.
Team Composition – Risk Assessment:
The team is multi-disciplinary and basically includes the roles as depicted
below
 Technical Role
 Supporting & Structuring Role
Technical personnel are from design, maintenance, process, quality &
Environment

Scope:
a) Total process operations within the plant
b) calamities/disasters/ mishaps which are, in general, associated with the
manufacturing facility are mentioned below
S.No. Hazard (Hazard Culmination)
01 HC Fire & explosion
02 HC Electrocution
03 HC Exposure affect by inhaling
04 HC Accidents
A general hazard grouping has been attempted below wherein various
operational areas capable of generating various hazards are shown. Total
process operation which is a continuous process is translated to flow chart. VIL
has total process / industrial activities classified into 7 categories any of which
could generate different type of hazard.
S.No Hazard grouping (Potentially hazardous operational area)
01 HP Material/ Product handling & transportation
02 HP Material/ Product storage
03 HP Manufacturing process
 04 HP Maintenance operations
05 HP Electrical installation and cable net work
06 HP Civil structure & fabrication
07 HP Compressed air
Hazard Substances:
Hazards posed by the storage and handling of hazardous substances as
listed below are clubbed along with various hazard groups (activities). The
substances in VIL are LDO, HSD, LPG cutting gas – flammable & explosive
Chrysotile asbestos fibre - Exposure affect over a prolonged period

Identified Areas with Hazard Potential:

This clause explains various activities / parameters under different hazard
zone, linked to various hazard grouping.

Fire& Explosion:
Activities / Parameters Hazard grouping
 All electric installation & transformer 05HP
 Cable network 05HP
 LDO & HSD Storage Tank 02HP
 LDO Spray system at stripping area 03,04 HP
 D G Room 05HP
 Compressed Air 07HP
 Close Chamber 03,04 HP
 LPG Distribution Room & burner unit 02,03,04 HP
 Oxygen & Acetylene gas cylinder 02,04,06,07 HP
 Gas cutting & welding 04,06,07 HP
 Less accessible yard within factory premises
& wit dry shrub & grass, especially in summer season -
(Note – As the process is mainly water based, fire hazard
limited to select areas only)

Electrocution
Activities / Parameters Hazard grouping
 Cable network within the plant 05HP
 Electrical installation& Transformer 05HP
Exposure Effect
Exposure to dust (Cement, fly ash & asbestos) by inhaling, is likely to
occur in the following areas.
Activities / Parameters Hazard grouping
  Receipt & storage of Cement & FA 02HP
 Receipt & storage of Asbestos 02HP
 Cement feeding to silo 03HP
 F A bagging & weighing 03 HP
 Asbestos milling & storing 03,04 HP
 R M slurry preparation 03HP
 Layer formation 03HP
 Product formation 03HP
 Waste water storage & recycling 02,03,06HP
 Solid waste storage & recycling (Sludge) 01,02,03,06HP
 Solid waste disposal 01,03,06HP
 Wet waste recycling (Green) 03,4, HP
 Sheet cutting & Finishing 01,03,04HP
 Dry waste storage 02,03, HP
 Sheet pulverization to HGW 01,03,04Hp
 HGW bagging, weighing & Storage 02,03HP
 HGW recycling 01,03HP
 From PC facilities 02,03,04HP

Accident:
Accident other than fire explosion or electrocution, causing injury or
Loss of life to a person could occur from the activities of any of the
Hazard grouping.
Exposure Effect:
Exposure to Cement & FA Dust:
 Dust collection equipment not running.
 Protective wears not worn.
Exposure by inhaling to asbestos:
 Torn bags during unloading.
 Faulty packing design causing tipping over of fibre bags.
 Torn bags during process operation.
 Forklifts mal-operation.
 Fibre spillage through fibre handling equipment (e.g. SBO, Shredder
units, screw conveyor, elevator, Des).
 Dust Collector not running.
 Improper handling & disposal of asbestos containing wastes.
 Elect/Mechfailure causing process water overflow/leakage.
 Improper dust suppression at sheet cutting/finishing area.
  Work ethics/practices.

Mandatory Approvals/Licenses:
Statutory regulation followed and license/consent/permission obtained
on the storage/installation of following items.
 LDO & HSD – Storage license under Indian Explosive Act.
 HSD & Lubricants-Purchase/sell/storage license under Petroleum
Products Licensing & Regulation – 80.
 LPG
 DG Set – Permission from Electricity Board and consent from State
Pollution Control Board.
 Electric Substation} Permission from Electrical safety inspectorate.
 Transformer.
Periodic inspection by the statutory body / III party on the following.
 Lifting Machines – Chain pulley block & crane Form 37
 Lifting Machines – Fork Lifts Form 37
 Pressure Vessels – Air pressure Form 8
 Dust Collector – On all electrical installations
Panels, cable laying, earthing status Form 27A
Regular & periodic inspection carried out on the following.
 LPG Storage, distribution & burning.
 Electric Panels
 Cable laying
 DG set critical parameters.
Installation & regular inspection of fire extinguishers at strategic points (Refer –
Fire Control record)
Regular fire drill & training conducted.
(Refer Safety Training Record)
Warning signs displayed prominently at critical points.
System audits conducted against SOPs &Wls.
Skills needs analysis and training carried out regularly.
Training& Counseling:
 Training & Counseling imparted on the following.
 Electrical Safety.
 Safe work practices.
 Discard suspect instruments.
 Thick rubber sheet provided on floor as insulation (in DG Room)
and at near Electrical panels.
 Sign boards prominently displayed.
 One Fire Extinguisher installed in critical area.
 Regular & periodic inspection of Electrical installation, cable laying
work, and compliance to statutory requirement for all electrical
installation carried out.
 Consent (permission obtained from statutory bodies for DG Set).
Raw Materials Exposure Effect:

Asbestos Fibre (Chrysotile):

Fibre bags handled in a mechanized way in automatic bag opening device
erected with dust collector. Fibre emission levels are maintained less than 0.1
fibre/cc. Empty bags are shredded and recycled into the process. From milling
the process is entirely in wet condition. Transportation, packing & storage as per
international norms and also as per BIS standards.
(Refer *RTM * IS 12079-87)
1 Periodical inspection of PC equipment’s, both by in-house and third Party
(Refer Dust Collector Record & Form 27A)
2 Regular air monitoring carried out. (ambient & personal)
3 Waste water totally recycled.
4 Solid waste disposal as per BIS guidelines (Ref:IS:11768-86)
5 Dry waste being recycled after pulverization under controlled condition
(Ref-IS: 11768-86)
6 Consent Order obtained from PCB, for Air & Water.
7 Authorization for hazardous waste management obtained from PCB.
8 All fibre handling equipment are closed one and connected to dust
extraction system.
 9 Medical surveillance of every worker both periodic and at cessation of
employment being carried out, (Ref-IS: 11451-86).
10 Warning signs displayed.
11 Protective wears always available.
12 Awareness on asbestos – hazard made far & wide by continuous training
& counseling.
Cement & Fly Ash:
Cement is feed in tankers, Conveyed to silos pneumatically. Silos are equipped
with dust collectors.
1. Dust extraction system installed at cement feeding
section.
2. Air monitoring of cement stack carried out.
3. Protective wears available.
General:
i. SOP’s & WI areavailable for all sections.
ii. Caution labeling & display boards placed at strategic locations.
iii. Plant, machinery &equipment are made to the drawings which are
available with design section.
iv. System audit, section wise being done periodically.
v. Safety classes being taken regularly.
Study & Review:
I. Study reports designed for various activities/parameters under
different hazard grouping. The report is check listed and
recommends/follows/reviews the action taken/proposed/deferred.
II. The reports are presented before top management.
There is no storage of highly inflammable substances like Furnace oil, HSD in
the plant, also there is no proposal. Hence risk analysis on those substances is
not required