P FD File

M/s. SOLID PLY (P) LTD.
PROPOSAL FOR RESIN MANUFACTURING PLANT

NEW FOR ENVIRONMENTAL CLEARANCE
M/s. REGAL PLYWOOD INDUSTRIES PVT.

LTD.
Site Address : Sy. No: 234/4 & 236/1, Vellanki Village,
Anandapuram Mandal, Visakhapatnam District.
Proposed Capacity: Manufacture of Resins with 3.5 Tons/day

(1000 Tons/annum) Capacity
Existing Capacity: Plywood – 350 TPM and Veneer – 500 TPM
Sector : 21 - 5(f) – Synthetic organic chemicals industry (dyes &

dye intermediates & bulk drug and intermediates)
PREPARED BY
SV ENVIRO LABS & CONSULTANTS
Visakhapatnam
Phone: 0891-2755528, Fax: 0891-2755529
Email: svenviro_labs@yahoo.co.in
Recognized by MoEF&CC and QCI –Accredited,
NABET accredited Dt: 28.09.2020 & extended upto 24.04.2021.
NABL Accredited Dt: 08.05.2017 valid up to 07.05.2019& 19.7.19 – 18.7.2021
MoEF Recognized Dt: 02.06.2016 valid up to 01.06.2021
M/s. REGAL PLYWOOD INDUSTRIES PVT. LTD.
1.0 INTRODUCTION
M/s. Regal Plywood Industries (P) Limited established at Sy. No. 234/4 & 236/1, Vel-
lanki Village, Anandapuram Mandal, Visakhapatnam District, Andhra Pradesh.
The industry has obtained CFO vide Order No. 7294/APPCB/ZO-

VSP/VSP/CFO/W&A/2018-1488 Dated 25.01.2018 for the manufacture of plywood.
We have also obtained CFO for manufacturing resin vide Order No.
7294/APPCB/ZO-VSP/CFO/W&A/2018-Dt. 06.03.2018 and during the application
we never came across EC applicability and so such condition was laid in orders, and
we were also layman in procurement of EC due to unknowingly lack of knowledge.
We have stopped resin production after realizing the unit is listed under category of
5(f) of EIA notification, 2006 which require Environmental Clearance and will not
manufacture resin without obtaining EC. The same was intimated to the APPCB Zon-
al Office and Member Secretary, State Environmental Impact Assessment Authority,
Andhra Pradesh vide Letter to APPCB Zonal Office Dated 02.12.2020 and Letter to
Member Secretary, State Environmental Impact Assessment Authority, Andhra Pra-
desh Dated: 02.12.2020.
From humble beginnings as plywood traders in 1970s, M/s. Regal Plywood Industries
(P) Limited has grown over the years to establish itself as a leading Plywood manu-
facturer in India. With our manufacturing unit at the port city of Visakhapatnam, the
company has the location advantage of an efficient sea port along with vastly orga-
nized transport facilities connecting every nook and corner of the country.
The company has clear, transparent and explicit policies of acquiring the best availa-
ble raw materials for plywood.
Now the industry proposes to obtain Environmental Clearance under B2 category for
manufacturing of Resin plant with 3.5 Tons/day (1000 Tons/annum) capacity as per
Ministry of Environment, Forest and Climate Change Notification F.No.22-93/2017-
IA.III Dated 10.04.2019.
1.1 NEED OF THE PROJECT:

Phenolic resin is found in many of the industrial products like plywood, block board,
flush doors, decoratives. Usage of phenolic resin enhances the bonding property of the
raw material used to make plywood. It increases the products resistance against water.
Melamine resin is a hard, thermosetting plastic material made from Melamine and
Formaldehyde by polymerization. Melamine resin is often used to saturate decorative
paper that is laminated under heat and pressure and then pasted onto particle board;
the resulting panel is often called melamine and commonly used in ready‐to‐assemble
furniture and kitchen cabinets.
Urea Formaldehyde is used in many manufacturing processes like ply wood, block
board, decorative laminates. It is also used to glue wood together. Urea formaldehyde
was commonly used when producing electrical appliances casing.
1.2 BRIEF DESCRIPTION OF NATURE, SIZE, LOCATION OF THE PROJECT

1.2.1 Nature, Size & Location of the Project
The project site is situated at Sy. No: 234/4 & 236/1 located at Vellanki Village,
Anandapuram Mandal, Visakhapatnam District. The project site falls in the SOI top-
osheet No. 65 O/5 and lies between the Latitude: 17.889633° & Longitude
83.393657°. The location of the project site index, and google image and topomap is
appended in Figure 1 &2. The project salient Features are represented in the follow-
ing Table 1.
Table 1: Boundary Coordinates:
S. No Latitude Longitude
1 17.888976° 83.393879°
2 17.889359° 83.393333°
3 17.889432° 83.392972°
4 17.890490° 83.393511°
5 17.889655° 83.394370°
Fig 1: Google map around 10 km radius

Fig 2: Topo map around 10 km radius

Table 2: Salient features of the project

S. No Particulars Details
1. Name of the M/s. Regal Plywood Industries (P) Limited
Project
2. Production Ca- Proposed Resin Production Details:
pacity Phenol Formaldehyde Resin/Urea Formaldehyde Resin/
Melamine Urea Formaldehyde Resin/Melamine Formaldehyde Resin
– 3.5 Tons/Day
Existing Plywood Production Details:
Plywood – 350 TPM
Veneer – 500 TPM
3. Total Land Area The plant is spread over a total area of 2.93 Acres
4. Location of the Sy. No: 234/4 & 236/1,
Project Site Vellanki Village,
Anandapuram Mandal,
Visakhapatnam District
5. Nearest habita- Vemulavalasa Village at 1.34 Km
tion
6. Nearest town / Thagarapuvalasa at a distance of 5.28 km from the project site
city
7. Nearest Airport Visakhapatnam Airport at a distance of 25.31 km
8. Nearest High- National Highway – 16 is present at 1.04 km.
way
9. Nearest Port Visakhapatnam Port Trust at 23.87 Km.
10. Water Bodies Pond – 0.5km – N
Pedda Gedda – 2.45km - S
Gostani River – 4.33km – NE
Tatituru Cheruvu – 3.93km – NW
Katamani Cheruvu – 7.20 km – NW
11. Reserved / Kambalakonda Reserve Forest – 4.13 km – SW
Amanam R.F. – 8.82km - NE
Protected For-
ests
12. Archeologically Nil within 15 km radius
Important Places
13. National parks Kambalakonda Wildlife Sanctuary – 4.13 km SW

/ Wildlife Sanc-
tuaries/ Eco sen-
sitive zones as
per Wild Life
Protection Act,
1972
14. Seismic Zone Zone II– Moderate Zone
15. Defense Instal- Nil within 15 km radius
lations
1.3 LAND AREA BREAK-UP

The detailed breakup of the land for various activities at the project site is given in
the below Table 3.
Table 3: Land Break-up details
S. No. Facility Area
1 Builtup area (Existing) 4754.0 Sq.m.
2 Builtup area (Proposed) 116.13 Sq.m.
4 Greenbelt (Existing) 2492.40 Sq.m.
5 Greenbelt (Proposed) 1469.28 Sq.m.
6 Open area 2916.12 Sq.m.
7 Parking Area 131.42 Sq.m.
Total 11879.35 Sq.m.
2.0 EXISTING PRODUCTION DETAILS AS PER CFO ORDER:

S.No Name of the Product Quantity
1 Veneer 500 TPM
2 Plywood 350 TPM
PROPOSED PRODUCTION DETAILS:

1 Phenol formaldehyde Resin/Urea 3.5 Tons/Day
Formaldehyde Resin/Melamine Urea (or) 1000 Tons/annum
Formaldehyde Resin/Melamine For-
maldehyde Resin
EXISTING RAW MATERIAL DETAILS:

1 Timber (Euclyptus) 880 Tons/month
2 Core Veneer 200000 Sq.m/month
3 Gurjan Face Veneer 200000 Sq.m/month
PROPOSED RAW MATERIAL DETAILS:

1 Formalin 2450 kgs/day
2 Melamine 1137.5 kgs/day
3 Urea 1050 kgs/day
4 Caustic Soda 147 kgs/day
5 Phenol 1190 kgs/day
6 Poly Vinyl Acetate 17.5 kgs/day
7 Acetic acid 7 kgs/day
3.0 MANUFACTURING PROCESS:

3.1 Existing Plywood Manufacturing Process:
The manufacture of plywood consists of the following processes: log storage, log de-
barking and bucking, peeling the logs into veneers, drying the veneers, gluing the ve-
neers together, pressing the veneers in a hot press, plywood cutting, and other finish-
ing processes such as sanding.
Wooden logs in appropriate sizes are received from local suppliers. The initial step of
debarking is accomplished by feeding logs through one of several types of debarking
machines. The purpose of this operation is to remove the outer bark of the tree with-
out substantially damaging the wood.
Veneer moisture is checked against the target moisture level as the veneer exits the
veneer dryer. Veneer redryers may be used to redry the veneer that did not reach the
target moisture content. After drying, veneers are glued together on the edges to form
larger sheets of veneer. This process is called composing. Narrow veneer slices must
be composed before they are used in plywood panels or other products requiring wid-
er veneer sheets. When the veneers have been dried to their specified moisture con-
tent, they are conveyed to a layup operation, where resin is spread on the veneers. The
two main types of resins are phenol-formaldehyde, which is used for softwood ply-
wood and exterior grades of hardwood plywood, and urea-formaldehyde, which is
used to glue interior grades of hardwood plywood. The resins are applied by glue
spreader systems. Spreaders have a series of rubber-covered grooved application rolls
that apply the resin to the sheet of veneer. Generally, resin is spread on two sides of
one ply of veneer, which is then placed between two plies of veneer that are not coat-
ed with resin. Assembly of the plywood panels must be symmetrical on either side of
a neutral center in order to avoid excessive warpage.
For example, a five-ply panel would be laid up in the following manner. A back, with
the grain direction parallel to the long axis of the panel, is placed on the assembly ta-
ble. The next veneer has a grain direction perpendicular to that of the back, and is
spread with resin on both sides. Then, the center is placed, with no resin, and with the
grain perpendicular to the previous veneer (parallel with the back). The fourth veneer
has a grain perpendicular to the previous veneer (parallel with the short axis of the
panel) and is spread with resin on both sides. The final, face, veneer with no resin is
placed like the back with the grain parallel to the long axis of the plywood panel.
The laid-up assembly of veneers then is sent to a hot press in which it is consolidated
under heat and pressure. Hot pressing has two main objectives: (1) to press the glue
into a thin layer over each sheet of veneer; and (2) to activate the thermosetting resins.
Typical press temperatures range from 132° to 165°C (270° to 330°F) for softwood
plywood, and 107° to 135°C (225° to 275°F) for hardwood plywood. Press times gen-
erally range from 2 to 7 minutes. The time and temperature vary depending on the
wood species used, the resin used, and the press design. The plywood then is taken to
a finishing process where edges are trimmed; the face and back may or may not be
sanded smooth. The type of finishing depends on the end product desired
Plywood process flow diagram

3.2 Proposed Resin Plant Manufacturing Process:

Manufacturing process including chemical reaction, mass balance and process flow
diagram is described below;
Phenol Formaldehyde Resin (Single Stage):
a. Manufacturing Process
The manufacturing process is summarized below:
 Take required quantity of Phenol, Formaldehyde (37%) and Caustic Soda in
the reaction vessel and start steam heating until the temperature reaches at 58
°C to 60 °C.
 Temperature will increase up to 90 °C. Once the temperature reaches up to
90 °C then cut the steam supply. Reflux process will be start at this point to
achieve required water tolerance.
 After achieving required water tolerance, start cooling to decrease
temperature up to 60 °C. Once the temperature reach at 60 °C stop cooling
and start heating for distillation process for required quantity of resin.
 After achieving required amount of resins start cooling to obtain final
product. Final product will be checked for the properties like viscosity, pH,
gel time etc.
Process Flow Diagram:
Requirement of material:
ONE TON BASIS
Phenol 340 kgs

Formalin 612 kgs
Caustic Soda 21 kgs
Water 42 litres
Phenol Formaldehyde Resin (Double Stage):

a. Manufacturing Process
 Step 1 - 320 kgs of phenol, 180 kgs of formalin and 18 kgs of caustic soda is add-
ed along with 60 litres of water in the kettle. Temperature is raised up to 90 de-
grees for 1½ hours and then it is brought down to 55 degrees.
 Step 2 – 24 kgs of Caustic + 120 liters of water + 5 kgs PVA is added and again
temperature is brought down to 50 degrees. Then remaining part of formalin i.e.,
330 kgs is added, and temperature is maintained at 84 – 86 degrees for two hours.
When required viscosity is received, cooling is started brought down up to room
temperature and the finished product is unloaded.
ONE TON BASIS

Phenol 320 kgs
Formalin 510 kgs
Caustic Soda 42 kgs
Water 180 litres
PVA 5 kgs
Melamine Formaldehyde Resin:

Manufacturing Process:
 The Formaldehyde (37%) is charged into reaction vessel and raises its pH up
to 8.5 – 9.0 by adding Caustic Soda solution.
 Then Melamine is charged into vessel thoroughly to maintain the pH up to
8.5 – 9.0. Heat is supplied and raised temperature up to 82 °C. Maintain 82°C
at pH 8.5 – 9.0 for 90 minutes till the precipitation is observed.
 Check the flow time in hot condition with B4 cup till it around 14.5 sec. Then
take reaction at pH 9.0 by adding Caustic Soda solution. The mixture is cooled
at 60 °C and cooling continued up to 40 °C by circulating cold water.
 Finally, check viscosity, tolerance, pH, turbidity etc. to obtain desired product
property.

ONE TON BASIS

Formalin 650 kgs
Melamine 325 kgs
Caustic Soda 3 kgs
Water 6 litres
Urea Formaldehyde Resin:

 The polymerization reaction of Urea Formaldehyde Resin takes places in two
stages. The first stage is an addition polymerization in which Urea &
Formaldehyde (37%) undergo addition reaction, which takes place in
neutral or slightly alkaline condition at pH 7.5 to 8.0 at elevated temperature
95 °C to 100°C.
 Methyl Urea formed in the first stage are allowed to reach further by
lowering pH 4 to 6 using Acetic Acid where reaction takes place faster and
leads to the formation of long chain polymer.
 The reaction is allowed to proceed further up to the desired viscosity and the
reaction is arrested midway by raising the pH of the resin solution to 7.5 to
8.0 using Caustic Soda and then the reaction is cooled down to the room
temperature and stored in sealed container.
 Check viscosity, tolerance, pH, gel time of the required batch of the resin.
Reaction vessel
ONE TON BASIS

Formalin 700 kgs
Technical Urea 300 kgs
Caustic Soda 4 kgs
Water 4 litres
Acetic acid 2 kgs
Melamine Urea Formaldehyde Resin:

 Urea and formaldehyde are charged to reactor.
 Than caustic soda solution is added to maintain pH. 9-9.5 with stirring.
 Thereafter required quantity of Malamine is added and reaction temperature is main-
tained at 95°C.
 Reflux is done for 30 minutes.
 After obtaining turbidity increase pH 9-9.5 by adding caustic soda solution. After get-
ting desired water tolerance 1:3-1:4, start cooling.
 Add 2nd batch urea of 70°C & 3rd batch urea at 60°C.
 Cool the whole mass at 40°C and maintain pH 8-8.5 and store it as final product.
ONE TON BASIS

Formalin 645 kgs
Melamine 225 kgs
Urea 150 kgs
Caustic 4 kgs
Water 4 litres
4.0 UTILITIES, RESOURCE REQUIREMENTS AND ASSOCIATEDFACILITIES

4.1 WATER CONSUMPTION
Water is required for process & washings and domestic purposes. The required water
will be withdrawn from water tankers. The details of water requirement are tabulated
below:
Table 4: Fresh water requirement for existing:
S.No. Description Fresh water requirement
1. Washings 0.1 KLD
2. Domestic 0.5 KLD
Industrial Cooling (Re-
3. 2.0
circulation)
Total 2.6 KLD
Table 5: Fresh water requirement for Proposed:

S.No. Description Fresh water requirement
1. Process & Washings 1.0 KLD
2. Domestic 0.7 KLD
3. Cooling tower makeup 0.6 KLD
4 Gardening 1.5 KLD
Total 3.8 KLD
Note: For gardening purpose storage pond water will be utilized and greenbelt
will be developed with less water consumption plants.
Table 6: Waste water generation for existing:

S.No. Description Waste water generation Point of disposal
1 Domestic 0.3 KLD Septic tank followed by soak
pit
2 Washings -- After treatment shall be uti-
lized for onland irrigation
Total 0.6 KLD
Table 7: Waste water generation for Proposed:

S.No. Description Waste water generation Point of disposal
1. Process& Washings 0.5 KLD Washings water will be
recycled
2. Domestic 0.56 KLD Septic tank followed by
soak pit
Total 1.06 KLD
Table 8: Effluent characteristics before and after treatment

S.No. Parameter
Value
1 pH 6.0-11.0
2 TSS (mg/l) 500-700
3 TDS (mg/l) 4000-6000
4 COD (mg/l) 11000-13000
5 BOD (mg/l) 5000-6500
4.2 RAINWATER HARVESTING AND STORM WATER MANAGEMENT

The industry proposes to develop water harvesting structure to harvest the run-off wa-
ter for recharge of ground water. Roof top water collection will be adopted wherever
possible and collected rainwater returned to raw water storage tank to reused for plant
operations. The storage tank and the sump shall get refilled during intense rain fall pe-
riods, and the stored water shall be reused mainly during monsoon and post monsoon
seasons.
4.3 AIR QUALITY MANAGEMENT

In this unit, flue gas emission will be the main source of air pollution. There will not
be any type of process gas emissions during the manufacturing of resins. There will
be chances of fugitive emission due to raw material handling, transportation and man-
ufacturing activity. Various potential of air pollution are described below under re-
spective heading.
S.No. Details of Stack Stack-1 Stack-2 Stack-3
1 Attached to Thermic Fluid DG Set DG Set
Heater
2 Capacity 2x10 Lakh K. cal/hr 1 x 185 KVA 1 x 63 KVA
3 Fuel Furnace Oil HSD HSD
4 Control Equip- Bag Filter Acoustic Enclo- Acoustic En-

ment sure and adequate closure and
Stack height adequate Stack
height
4.3.1 Fugitive emissions:

Due to raw material handling, transportation and manufacturing activity, there will
be chances of fugitive emissions. However, unit will take all the necessary precau-
tions and control measures to take care of the fugitive emissions due to the proposed
project:
 All the raw materials will be stored in isolated storage area and containers will
be kept tightly closed.
 All the motors of pumps for the handling of hazardous chemicals will be flame
proof and provided with suitable mechanical seal with stand‐by arrangement.
 The control of all parameters on a continuous basis will be done by adequate
control valves, pressure release valves and safety valves etc.
 All the flange joints of the pipe lines will be covered with flange guards.
 Precautionary measures will be taken while handling various hazardous chem-
icals. There will also be provision of adequate ventilation system in process
plant and hazardous chemical storage area.
 A regular preventive maintenance will be planned to replace or rectify all gas-
kets, joints etc.
 TREM card will be provided to the driver during the transportation of Hazard-
ous raw materials/products.
 Sufficient information and training regarding characteristics and immediate
actions in case of any spillage or accident during transportation of hazardous
chemical will be provided to the driver.
 The unit will also develop green belt area within the factory premises to con-
trol the fugitive emissions from spreading into surrounding environment.
 Unit will install portable detection system for hazardous chemical like Phenol,
and Formaldehyde in process area.
 Moreover, Unit will carry out regular work place monitoring.
4.4 MANPOWER
The manpower requirement for the existing and present proposal is expected to gener-
ate some permanent jobs and secondary jobs for the operation and maintenance of
plant. This will increase direct/ indirect employment opportunities and ancillary busi-
ness development to some extent for the local population. The manpower requirement
including both technical and non-technical personnel is presented in Table 9.
Table 9: Manpower Requirement

S.No. Description Existing Proposed
1. Employment 87 6
Total 87 6
4.5 NOISE QUALITY MANAGEMENT

Noise – unwanted and unpleasant sound.
The main source of noise in the plant is due to the operation of
machineries & D.G. sets. However, unit will take following adequate
precautionary measure for noise and vibration control;
 Latest technology based low noise D.G. set with acoustic enclosures installed.
 All the vibrating parts will be checked periodically and serviced to reduce the
noise generation.
 Proper and timely oiling, lubrication and preventive maintenance will be carried
out for the machineries and equipment to reduce noise generation.
Ear muffs/ earplugs will be provided to the workers working under high noise area
to minimize the adverse effect on the health.
 The transport contractor will be informed to avoid unnecessary speeding of vehi-
cles inside the premises.
 Noise monitoring will be done regularly at prominent places in the plant.
 Proposed greenbelt area will help to prevent the noise pollution outside the
premises.
4.6 SOLID WASTE MANAGEMENT

The details of hazardous waste generation and handling / Management are given in
below table.
Table 10: Quantity and disposal plan of solid & hazardous wastes
S.No Description Existing Proposed Mode of disposal
Quantity Quantity
1. Used Oil 100 LPM -- APPCB authorized agencies
2. Carboys -- 100 Nos/annum APPCB authorized agencies
3. Drums -- 50 Nos/annum APPCB authorized agencies

4.6.1 Mitigation Measures for Impacts on Environment during Construction Phase

During construction phase, major impacts anticipated will be increase in dust
contamination and noise. However, the impacts of the construction period will be
localized and limited up to the construction phase. Impacts during construction phase
and its mitigative measures.
Attributes Impacts causing fac- Mitigative Measures

tors/Impacts
Air  Vehicular emissions –  Specific control measures on vehicular-
smoke, gaseous and PM movement, emissions and noise from
vehicles
 PM emissions from site
 Good practices for construction, loading and
activities and handling
unloading of materials,
and storage of construc-
o Storage in pre‐designated areas
tion materials
o Enclosures/barriers around site activities
and storages
Noise  Vehicular  Vehicular maintenance
 Construction machinery  Standard machinery
 Activities  Good construction practices and suita-
ble enclosures/barriers
o Avoid high noise generating
activities, vehicular movement and
operation of machinery during
nighttime
Water  water discharge from  Good construction practices will be

construction activities adopted to minimize water wasting and
pollution.
Socio- Expectations/aspirations Assessing local skills availability & the skills

economy of local people required for construction related activities &
giving preference to local persons for job
Ecology  Loss/degradation of  Avoid flowering season for site activities

local floral species  Control of noise & vehicular movement
in pre‐defined areas
 Avoid night time working
4.6.2 Mitigation Measures for Impacts on Environment during Operation Phase
Attributes Impacts causing fac- Mitigative Measures

tors/Impacts
Deposition of PM from stack ,
Land use  Specific dust control measures
preparation & storage,
discussed under air & water
vehicular movement on
environment
unpaved surfaces
 Specific dust control measures at
source like paved roads, defined
traffic routes, etc.
Air  PM, SO2, NO2, CO emissions  Tarpaulin covered vehicles.

Environment
from flue gas stacks.  Bag Filter are installed to reduce pollu-
 Fugitive emission during tion.
handling of Product and RM.
Water Run off:

Environment  Surface run off from plant  Run off collection system, settling, recy-
species cling/reuse of clear water
 Storm water  Storm water collection &
disposal network.
Noise & Noise from  Specific acoustic enclosures
Vibration  Industrial equipment, pumps  Good design & engineering
practice like specific foundations
& mountings to control
vibrations.
Ecology and  Effect on flora & fauna Specific control measures for
Biodiversity because of changes in soil, drainage & water quality,
drainage pattern & water reduction in emission of PM,
quality and increase in PM, & reduction in noise & vibration
noise and vibration levels
 Enumeration of loss of flora &
 Inhibition of growth & fauna, and compensation
vegetation due to PM & measures, if applicable
vehicular emissions
Socio‐  Health issues among nearby  Specific control measures for

Economic population due to gaseous gaseous emissions and PM from
emissions & PM in ambient stack & fugitive emissions
air.  Beneficial for local population
 Opportunity for local  Inevitable, growth could be
population for employment planned, beneficial to land
based on their skills & to owners, increase in prices of real
supply materials & services estate is unavoidable.
Injuries from equipment Occupational health & safety
Occupational  Electrical hazards from related measures in accordance
Health & switch gears and other with the applicable regulations like
sources Factories Act to include.
Safety
 Exposure to high Good work environment
temperature First‐aid facilities
 Exposure to high noise Masks with suitable canisters
PPEs
4.7 BIOLOGICAL ENVIRONMENT

Green belt development is one of the most effective environmental pollution control
measure. Trees play vital role in the environment in preventing the horizontal disper-
sion of the pollutants to the surrounding areas. They are very effective in trapping the
pollution causing agents viz. dust and gaseous pollutants. They are also considered to
be excellent indicators of excessive ground level concentrations. The green belt is be-
ing proposed for the following objectives.
 Mitigation of fugitive dust emissions
 Noise pollution control
 Prevention of soil erosion
 Balancing eco environment
 Aesthetics
In view of this, the list of species to be planted in the green belt area is illustrated be-
low. Mixed plantation shall be done keeping optimum spacing between the saplings.
Action plan for proposed trees in tree plantation area

 Eucalyptus globulus
 Pongamia Pinnata
 Ficus benghalensis
 Syzygium cumini
 Azadirachta indica
4.8 SOCIO-ECONOMIC ENVIRONMENT

The proposed resin manufacturing plant will provide an opportunity for the local peo-
ple to get employment directly or indirectly and helps in the up-liftment of the socio-
economic status of the area. The project proponent proposes for skill development
training programme to the unemployed youth and betterment of neighbouring social
conditions through environmental awareness and welfare programs.
5.0 PROJECT SCHEDULE AND COST ESTIMATE

Existing Project Cost Details:
S.No. Description Cost
1 Land 12.89 Lakhs
2 Building 52.32 Lakhs
3 Plant & Machinery 128.75 Lakhs
Total 193.96 Lakhs
Proposed Project Cost Details:

S.No. Description Cost
1 Building 10.0 Lakhs
2 Plant & Machinery 25.0 Lakhs
Total 35.0 Lakhs
6.0 COST ESTIMATE FOR ENVIRONMENTAL MANAGEMENT PLAN

The management of M/s. Regal Plywood Industries Private Limited is quite conscious
of its responsibility for maintaining clean and a healthy environment. The manage-
ment is also keen make efficient measures towards suppression of pollution sources. It
is estimated that the capital cost for implementing the Environment Management Plan
is Rs.5.9 Lakhs and Recurring cost per annum is Rs. 3.3 Lakhs. The cost estimate is
presented in Table 11.
Table 11: Environmental Management Budget

Recurring Cost per
Capital Cost
S.No. Description annum
Lakhs
Lakhs
1. Air pollution Control 2.0 1.0
2. Water pollution Control -- --
Environmental Monitoring and Manage-
3. -- 0.5
ment
4. Occupation Health 0.6 0.3
5. Greenbelt 2.5 0.6
6. Rain Water Harvesting -- 0.5
7. Solid & Hazardous Waste 0.8 0.4
Total 5.9 3.3
7.0 CORPORATE ENVIRONMENTAL RESPONSIBILITY

M/s. Regal Plywood Industries Private Limited proposes Rs. 1.0 Lakh for CSR activi-
ty.
Fig 3: Site Layout

[Type the document title]
RISK ANALYSIS & DISASTER MANAGEMENT PLAN
M/s. REGAL PLYWOOD INDUSTRIES

PVT. LTD.
Site Address: Sy. No: 234/4 & 236/1,
Vellanki Village,
Anandapuram Mandal,
Visakhapatnam, Andhra Pradesh
Capacity: Proposal for Manufacture of Resins with 3.5 Tons/day
(1000 Tons/annum) Capacity
PREPARED BY
SV ENVIRO LABS & CONSULTANTS
Visakhapatnam
Phone: 0891-2755528, Fax: 0891-2755529
Email: svenviro_labs@yahoo.co.in
Recognized by MoEF&CC and QCI –Accredited,
NABET accredited Dt: 26.7.18 to 15.04.2020 & Extended upto 24.04.2021
NABL Accredited Dt: 08.05.2017 valid up to 07.05.2019& 19.7.19 – 18.7.2021
MoEF Recognized Dt: 02.06.2016 valid up to 01.06.2021
Risk Analysis & Disaster Management Plan
1.0 INTRODUCTION
M/s. Regal Plywood Industries (P) Limited established at Sy. No. 234/4 & 236/1,
Vellanki Village, Anandapuram Mandal, Visakhapatnam District, Andhra Pradesh.
The industry has obtained CFO vide Order No. 7294/APPCB/ZO-

VSP/VSP/CFO/W&A/2018-1488 Dated 25.01.2018 for the manufacture of plywood.
From humble beginnings as plywood traders in 1970s, M/s. Regal Plywood Industries (P)
Limited has grown over the years to establish itself as a leading Plywood manufacturer in
India. With our manufacturing unit at the port city of Visakhapatnam, the company has
the location advantage of an efficient sea port along with vastly organized transport
facilities connecting every nook and corner of the country.
The company has clear, transparent and explicit policies of acquiring the best available
raw materials for plywood.
Now the industry proposes to obtain Environmental Clearance under B2 category for
manufacturing of Resin plant with 3.5 Tons/day capacity (1000 Tons/annum) as per
Ministry of Environment, Forest and Climate Change Notification F.No.22-93/2017-
IA.III Dated 10.04.2019.
1.1 BRIEF DESCRIPTION OF NATURE, SIZE, LOCATION OF THE PROJECT

1.1.1 Nature, Size & Location of the Project
The project site is situated at Sy. No: 234/4 & 236/1 located at Vellanki Village,
Anandapuram Mandal, Visakhapatnam District. The project site falls in the SOI toposheet
No. 65 O/5 and lies between the Latitude: 17.889633° & Longitude 83.393657°. The
location of the project site index, and google image and topomap is appended in Figure
1.1 & 1.2. The project salient Features are represented in the following Table 1.1.
Table 1.1 : Boundary Coordinates
S. No Latitude Longitude
1 17.888976° 83.393879°
2 17.889359° 83.393333°
3 17.889432° 83.392972°
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4 17.890490° 83.393511°
5 17.889655° 83.394370°
Table 1.2: Salient features of the project

S. No Particulars Details
1. Name of the M/s. Regal Plywood Industries (P) Limited
Project
2. Production Proposed Resin Production Details:
Capacity Phenol Formaldehyde Resin/Urea Formaldehyde Resin/
Melamine Urea Formaldehyde Resin/Melamine Formaldehyde Resin
– 3.5 Tons/Day
Existing Plywood Production Details:
Plywood – 350 TPM
Veneer – 500 TPM
3. Total Land Area The plant is spread over a total area of 2.93 Acres
4. Location of the Sy. No: 234/4 & 236/1,
Project Site Vellanki Village,
Anandapuram Mandal,
Visakhapatnam District
5. Nearest Vemulavalasa Village at 1.34 Km
habitation
6. Nearest town / Thagarapuvalasa at a distance of 5.28 km from the project site
city
7. Nearest Airport Visakhapatnam Airport at a distance of 25.31 km
8. Nearest National Highway – 16 is present at 1.04 km.
Highway
9. Nearest Port Visakhapatnam Port Trust at 23.87 Km.
10. Water Bodies Pond – 0.5km – N
Pedda Gedda – 2.45km - S
Gostani River – 4.33km – NE
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Tatituru Cheruvu – 3.93km – NW

Katamani Cheruvu – 7.20 km – NW
11. Reserved / Kambalakonda Reserve Forest – 4.13 km – SW
Amanam R.F. – 8.82km - NE
Protected
Forests
12. Archeologically Nil within 15 km radius
Important Places
13. National parks Kambalakonda Wildlife Sanctuary – 4.13 km SW

/ Wildlife
Sanctuaries/ Eco
sensitive zones
as per Wild Life
Protection Act,
1972
14. Seismic Zone Zone II– Moderate Zone
15. Defense Nil within 15 km radius
Installations
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Fig 1.1 Google map around 10 km radius
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Fig 1.2 Topo map around 10 km radius
Page 6
2.0 PRODUCTION DETAILS:

EXISTING PRODUCTION DETAILS AS PER CFO ORDER:
1 Veneer 500 TPM
2 Plywood 350 TPM
PROPOSED PRODUCTION DETAILS:

1 Phenol formaldehyde Resin/Urea 3.5 Tons/Day
Formaldehyde Resin/ (or) 1000 Tons/annum
Melamine Urea Formaldehyde
Resin/Melamine Formaldehyde Resin
3.0 RISK ASSESSMENT

The principal objective of the risk assessment study is to identify and quantify the major
hazards and the risk associated with various operations of the project, which may lead to
emergency consequences (disasters) affecting the public safety and health. Based on this
information, an emergency preparedness plan is to be prepared to mitigate the
consequences. The approach involves hazards identification, hazards assessment and
evaluation, developing Disaster Management Plan (DMP).
3.1.1 Objective of Risk Assessment

The main objective Risk Assessment is to determine the potential risks of major accidents
having damage potential to life and property and provide a scientific basis for decision
makers to be satisfied about the safety levels of the facilities to be set up. This is achieved
by the following:
 Identification of hazards that could be realized from the unit operations and other
activities.
 Identify the potential failure scenarios that could occur within the facility.
 Analyze the possible likelihood and frequency of such risk scenarios by reviewing
historical accident related data.
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 To assess, the potential risks associated with identified hazards to which the project
and its personal and community outside may be subjected. Consequences analysis of
various hazards is carried out to determine the vulnerable zones for each probable
accident scenario.
 Evaluate the process hazards emanating from the identified potential accident
scenarios.
 Analyze the damage effects to the surroundings due to such accidents.
 Conclusion and Recommendation to mitigate measures to reduce the hazard / risks.
 To provide guidelines for the preparation of On-site emergency plan.
3.1.2 Risk Assessment Methodology

Risk analysis consists of hazard identification studies to provide effective means to
identify different types of hazard during the operation of the facility. This is followed by
an assessment of the impacts of these hazards. Hazard is present in any system, plant or
unit that handles or stores flammable materials. The mere existence of hazards, however,
does not automatically imply the existence of risk. Screening & ranking methodologies
based on Preliminary Hazard Analysis (PHA) techniques have to be adopted for risk to be
evaluated.
Risk Analysis techniques provide advanced quantitative means to supplement other

hazard identification, analysis, assessment, control and management methods to identify
the potential for such incidents and to evaluate control strategies. The methodology
adopted for the study has been depicted in the Flow chart given below in Fig 3.1
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Fig 3.1 Risk Assessment Methodology
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3.1.3 Hazard Identification

A major hazard is defined as an event, which may have the potential to cause one or more
fatalities and also the potential to affect the integrity of the facility as a whole. The aim of
this step is to create a complete tabulation of identified hazards. Identification of hazards
in the project campaign is of primary significance in the analysis, quantification and cost
effective control of accidents involving chemicals and process. Hence, all the components
of a system/process need to be thoroughly examined to assess their potential for initiating
or propagating an unplanned event/sequence of events, which can be termed as an
accident.
Early detection of hazards and visualization of disastrous situation helps to impart

safety in a systematic way. The plants can continue to operate for many years and can
be modified several times in its life span, so due care must be given to avoid any
compromise on the safety concept included in the original plant design and operating
conditions. HAZOP is structured methodology, which allows its user to employ
imaginative thinking in the identification of hazards and operational problems. It involves
a systematic, methodical examination of design document that describe the facility. A
multidisciplinary team to identify hazards or operability problems that could result in an
accident performs the study. Deviations from the design value of key parameters are
studied, using guide words to direct the process of evaluation. This technique presumes
that the design values of flows, temperatures and other process variable are inherently
safe and operable.
Environmental Risk Assessment is a scientific analysis for identification of credible risk

and there after estimating the safe distances from any hazardous installations/processes in
the eventuality of an accident. Estimation of near-accurate safe distances is absolutely
necessary to protect the public, property and environment. Risk Assessment’ also known
as ‘Hazard Analysis’ and ‘Vulnerability Assessment’ is a procedure for identifying
hazards and determining their possible effects on a community and environment. Risk or
hazard by itself is not an event - it is the potential for an event.
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This section on Risk Assessment aims to provide a systematic analysis of the major risks
that may arise as a result of resins manufacturing by M/s. Regal Plywood Industries
Private Limited. The Risk Assessment process outlines rational evaluations of the
identified risks based on their significance and provides the outline for appropriate
preventive and risk mitigation measures. Results of the Risk Assessment provides
valuable inputs into the overall project planning and the decision making process for
effectively addressing the identified risks. This will ensure that the project risks stay
below As Low As Reasonably Practicable (ALARP) levels at all times during project
implementation.
Identification of Major Hazard Chemical

Identification of Major Hazard Installations Based on GoI Rules, 1989 as amended in
1994 & 2000. By Studying accidents occurred in industries in India over a few decades, a
specific legislation covering major hazard activities has been enforced by Government of
India in 1989 in conjunction with Environment Protection Act, 1986. This is referred
here as GOI rules 1989. For the purpose of identifying major hazard installations the rules
employ certain criteria based on toxic, flammable and explosive properties of chemicals.
a) Toxic Chemicals:
Chemicals having the following values of acute toxicity and which owing to their
physical and chemical properties are capable of producing major accidents
S.No. Toxicity Oral toxicity Dermal toxicity Inhalation toxicity
LD50 (mg/kg) LD50 (mg/kg) LC50 (mg/L)
1. Extremely toxic 1-50 1-200 0.1-0.5
2. Highly toxic 51-500 201-2000 0.5-2.0
b) Flammable Chemicals:
Flammable gases: Gases which at 20oC and at standard pressure of 101.3 KPa are:
1. Ignitable when in a mixture of 13 per cent or less by volume with air, or
2. Have a flammable range with air of at least 12 percentage points regardless of the
lower flammable limits.
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Flammable liquids:
i. Extremely flammable liquids: chemicals which have flash point lower than or
equal to 23oC and boiling point less than 35oC
ii. Very highly flammable liquids: chemicals which have a flash point lower than or
equal to 23oC and initial boiling point higher than 35oC
iii. Highly flammable liquids: chemicals which have a flash point lower than or equal
to 60oC but higher than 23oC
iv. Flammable liquids: chemicals which have a flash point higher than 60oC but
lower than 90oC.
c) Explosives:
Explosives means a solid or liquid or pyrotechnic substance (or a mixture of substances)
or an article which is in itself capable by chemical reaction of producing gas at such a
temperature and pressure and at such a speed as to cause damage to the surroundings;
Which is designed to produce an effect by heat, light, sound, gas or smoke or a
combination of these as a result of non-detonative self-sustaining exothermic chemical
reaction.
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3.1.4 Storage facilities of hazardous chemicals

The storage capacities / details of the major hazardous chemicals being used for
manufacturing various products are given in Table 3.1
Table 3.1 List of storage capacities / details of the major hazardous chemicals
CAPACITY DIA HEIGHT
S.No. SOLVENTS CHEMICAL NAME (MT) (M) (M)
1 SOLVENTS PHENOL 25 3.0 5.0
2 SOLVENTS FORMALIN 25 3.0 5.0
3.1.5 Fire & Explosion Index (F&EI)

F&EI is a rapid ranking method for identifying the degree of hazard. The application of
F&EI would help to make a quick assessment of the nature and quantification of the
hazard in these areas. Material factor (MF) of the material concerned, the General
Process hazards and Special Process Hazards associated with the product are taken into
consideration while computing, using standard procedure of awarding penalties based on
storage, handling & operating parameters.
F&EI is a product of Material Factor (MF) and Hazard Factor (F3). While MF represents
the flammability and reactivity of the substances, hazard factor (F3) is itself a product of
General Process Hazard (GPH) and Special Process Hazard (SPH). An accurate plot plan
of the plant, a process flow sheet and Fire and Explosion Index and Hazard classification
Guide published by Dow Chemical Company are required to estimate F&EI of any plant
or storage units.
By comparing the indices of F&EI, the unit under analysis is classified into one of the
following categories established for this purpose
Table 3.2 Categories of substances based on F&EI

F&EI Index Range Degree of Hazard
1-60 Light
61-96 Moderate
97-127 Intermediate
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128-158 Heavy
159 & above Severe
3.1.6 Hazard and Operability Study (HAZOP)

In Resins manufacturing industry there is a great awareness of the necessity to apply
more systematic approach to safety and ease of operation, particularly in design.
Addition, there is an increasing pressure from government & society to improve standards
of safety and for the protection of the environment. The major hazard identification tools
include checklists, Hazard indices (FEI & TI), what – if analysis and HAZOP.
Combinations of all these techniques have been used in this study.
Early detection of hazards and visualization of disastrous situation helps to impart safety
in a systematic way. The plants can continue to operate for many years and can be
modified several times in its life span, so due care must be given to avoid any
compromise on the safety concept included in the original plant design and operating
conditions.
HAZOP is structured methodology, which allows its user to employ imaginative thinking
in the identification of hazards and operational problems. It involves a systematic,
methodical examination of design document that describe the facility. A multidisciplinary
team to identify hazards or operability problems that could result in an accident performs
the study. Deviations from the design value of key parameters are studied, using guide
words to direct the process of evaluation. This technique presumes that the design values
of flows, temperatures and other process variable are inherently safe and operable.
This HAZOP guideword approach was originally developed by Imperial Chemical

Industries Ltd, (ICI); which was further modified and made user friendly by the American
Institute of Chemical Engineers – Center for Chemical Process Safety.
The Hazard & Operability Study results in:

 Assisting the management with information of where the potential hazard may exist and
facilitate recommendations towards improved safety.
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 Providing the safety – related documentation of every line and piece of equipment in the
plant, which is very useful when modifications are carried out.
 Furnishing a prioritized basis for subsequent risk analysis work.
If HAZOP study is performed and findings are subsequently implemented to mitigate the
risk, then it can be said that the plant is operating at comparatively lower risk than before
the study. HAZOP helps to find the “Weak link” in a plant and to provide a basis for
developing procedural or engineering controls to remove or lessen the risks from the
identified problem area.
3.1.6.1 Common Causes of Accidents

Engineering and Instrumental
Based on the analysis of past accident information, common causes of major chemical
plant accidents are identified as:
 Improper use of tools, equipment, facilities
 Unsafe or defective equipment facilities
 Poor house keeping
 Lack of proper procedures
 Lack of awareness of hazards involved
 Lack of guides and safety devices
 Lack of protective equipment and clothing
Failures of Human Systems

An assessment of past chemical accidents reveals human factor to be the cause for over
60% of the accidents while the rest are due to other plant component failures. This
percentage will increase if major accidents alone are considered for analysis. Major
causes of human failures reported are due to:
 Stress induced by poor equipment design, unfavorable environmental conditions,
fatigue, etc.
 Lack of training in safety and loss prevention.
 Indecision in critical situations.
 Inexperienced staff being employed in hazardous situations.
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The number of persons/materials are potentially exposed to a specific hazard zone is a

function of the population density and distribution near the accident location. The failure
rate data are presented in the following Table 3.3.
Table 3.3 Failure Rate Data

S.No. Item International Data
1. Process Controllers 2.4 x 10-5 hr-5
2. Process control valve 2.0 x 10-6 hr-1
3. Alarm 2.3 x 10-5 hr-1
4. Leakage at biggest storage tank 5.0 x 10-5 hr-1
5. Leakage of pipeline 1 x 10-7m-1 yr-1
6. Human failure 1 x 10-4(demand)-1
3.1.7 Maximum Credible Accident Scenarios (MCA analysis)

Maximum Credible Accident Analysis (MCA) defines the accident with maximum
damage distance, which is believed to be probable. However, it is necessary to carry out a
hazard analysis study to visualize the consequences of an unexpected release from
chemical plant, which consists of a number of process units and tank farm facilities. The
present study provides quantified picture of the potential hazards and their consequences.
Based on the storage quantities and properties of the chemicals, hazard identification has
been assessed.
 Pool Fire due to rupture / leakage
 Vapour cloud due to storage tank rupture
Failure Frequency:
The release scenarios considered above can be broadly divided into two categories
i. Catastrophic failures which are of low frequency and
ii. Ruptures and leaks which are of relatively high frequency
Vapor or liquid release from failure of gasket, seal and rupture in pipelines and vessels
fall in second category whereas catastrophic failure of vessels and full bore rupture of
pipelines etc., fall into first category. Typical failure frequencies are given in Table 3.4.
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Table 3.4 General Failure Frequencies

Item Mode of failure Failure frequencies
Pressure Vessel Serious leak 1.0*10-5/year
Catastrophic 3.0*10-6/year
Pipelines
= 50 mm dia Full bore rupture 8.8*10-7/m.year
Significant leak 8.8*10-6/m.year
> 50 mm = 150 mm dia Full bore rupture 2.6*10-7/m.year
> 150 mm dia Full bore rupture 8.8*10-8/m.year
hose Rupture/Failure 4.0*10-5/hr
Unloading arm Rupture/Failure 3.0*10-8/hr
Check valve Failure on demand 1.0*10-4/ on demand
Motor operated valve Failure on demand 1.0*10-3/ on demand
Flange Leak 3.0*10-4/year
Pump seal Leak 5.0*10-3/year
Gasket failure Failure 5.0*10-5/year
Process safety valve (PSV) Lifts heavily 4.0*10-3/year
Blocked 1.0*10-3/year
Lifts lightly 6.0*10-2/year
3.1.8 Consequence Analysis

PHAST Lite 7.11 version by DNV is used for prediction of risk for various scenarios. The
accidental release of hazardous chemicals leads to subsequent events, which actually
cause the damage. The damages are of three types
1) Damage due to heat radiation
2) Damage due to over pressure effects subsequent to explosion
3) Damage due to toxic effects
The type of damage and extent of damage depends on nature of chemical, the conditions
of release, atmospheric conditions and the subsequent events.
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The following criteria tables present heat radiation intensities, radiation exposure and
lethality, and damage due to peak over pressure is presented in Table 3.5, Table 3.6 and
Table 3.7 respectively.
Table 3.5 Damage due to Incident Radiation Intensities
Heat Radiation Type of Damage Intensity
S.No.
(kW/m2) Damage to Equipment Damage to People
100% lethality in 1 min.
1 37.5 Damage to process equipment
1% lethality in 10 sec.
Minimum energy required to ignite
50% lethality in 1 min.
2 25.0 wood at indefinitely long exposure
Significant injury in 10sec.
without a flame
Maximum thermal radiation intensity
3 19.0 allowed on thermally unprotected --
adjoining equipment
Minimum energy to ignite with a
4 12.5 1% lethality in 1 min
flame; melts plastic tubing
Causes pain if duration is longer
5 4.5 -- than 20 sec, however blistering
is unlikely (First degree burns)
Causes no discomfort on long
6 1.6 --
exposures
Source: Techniques for Assessing Industrial Hazards by World Bank
Table 3.6 Radiation exposure and lethality
Radiation Intensity Exposure Time
1% Lethality Degree Burns
(KW/m2) (seconds)
No Discomfort even
1.6 -- 0
after longer exposure
4.5 20 0 1st
4.5 50 0 1st
8.0 20 0 1st
8.0 50 <1 3rd
8.0 60 <1 3rd
12.0 20 <1 2nd
12.0 50 8 3rd
12.5 -- 1 --
25.0 -- 50 --
37.5 -- 100 --
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Table 3.7 Damage due to peak over pressure

Human Injury Structural Damage
Peak Over Pressure – Peak Over
Type of Damage Type of Damage
bar Pressure – bar
5-8 100% lethality 0.3 Heavy (90 % damage)
3.5-5 50% lethality 0.1 Repairable (10 % damage)
2-3 Threshold lethality 0.03 Damage of Glass
1.33-2 Severe lung damage 0.01 Crack of windows
50 % Eardrum
1-3.66 - -
rupture
Source: Marshall, V.C.(1977)’ How lethal are explosives and toxic escapes
3.1.8.1 Scenarios considered for MCA Analysis

Chemical Storage
The details of storages in the plant are given in Table 3.1 above, In-case of chemical
released in the area catching fire, a steady catching fire will occur. Failures in pipeline
may occur due to corrosion and mechanical defect. Based on the storage and consumption
of various chemicals the following failure scenarios for the plant have been identified for
MCA analysis and the scenarios are discussed below.
Heat radiation effects

When a non-boiling liquid spills, it spreads into a pool. The size of the pool depends on
the availability of the bund and obstacles. The heat load on objects outside a burning pool
of liquid is calculated with the heat radiation model. The average heat radiation intensity,
the diameter-to-height ratio dependent on the burning liquid, geometric view, distance
from the fire, relative humidity of air, horizontal or vertical orientation of the object
radiated with respect to fire are factored. All storage tanks in tank-farm area are provided
with dykes. The heat radiation effects of the chemicals shown below.
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Damage distance (Pool Fire) for Phenol (25 MT)
Fig 3.2 Heat Radiation damage distance – 25 MT Phenol

The intensity radii for pool fire reached maximum distance of 25.61 m as per weather category
5/D at radiation level of 4 KW/m2.
Table 3.8: Phenol tank pool fire radiation effects
Distance (m)
Category1.5/F Category5/D Category1.5/D
Radiation level 4 KW/m2 23.4867 25.6108 23.5552
Radiation level 12.5 KW/m 2 14.1805 17.554 14.2625
Radiation level 37.5 KW/m2 5.84398 7.0753 5.92851
Damage distance (Tank on fire) for Phenol (25 MT)
Fig 3.3 Heat Radiation damage distance – 25 MT Phenol

The intensity radii for tank on fire reached maximum distance of 29.4882 m as per weather
category 1.5/D at radiation level of 4 KW/m2.
Table 3.9: Phenol tank pool fire radiation effects
Distance (m)
Radiation level 37.5 KW/m2 21.2164 17.1244 21.5261
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Damage distance (Pool Fire) for Formalin (25 MT)
Fig 3.4 Heat Radiation damage distance – 25 MT Formalin

The intensity radii for pool fire reached maximum distance of 30.7081 m as per weather category
5/D at radiation level of 4 KW/m2.
Table 3.10: Formalin tank pool fire radiation effects
Distance (m)
Radiation level 37.5 KW/m2 Not Reached Not Reached Not Reached
Damage distance (Tank on fire) for Formalin (25 MT)
Fig 3.5 Heat Radiation damage distance – 25 MT Formalin

The intensity radii for tank on fire reached maximum distance of 33.7821 m as per weather
category 1.5/D at radiation level of 4 KW/m2.
Table 3.11: Formalin tank pool fire radiation effects
Distance (m)
Radiation level 12.5 KW/m 2 Not Reached Not Reached Not Reached
Radiation level 37.5 KW/m2 Not Reached Not Reached Not Reached
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Overpressure effects
When an unignited gas cloud mixes with air and reaches the flammable range and if the
cloud ignites a flash fire or flash fire explosion can occur. Since the burning time is
shorter, instead of heat radiation from a flash fire, peak overpressure as a function of
distance from the centre of the cloud is derived. In case of pipeline leaks, damage
distances due to overpressure effects are not observed. The values are found to be similar
as there are no pressurized storage tanks in the tank farm, and the over pressure distances
are contingent on the tank capacity.
3.1.9 Recommendations
Plants of this nature, which handle a variety of chemicals, face problems of fire and
vapour cloud explosions. It has been observed that the damage distances are more or less
confined to the plant area only. The following opportunities will be considered as a
potential means of reducing identified risks during the operation of the plant:
 Provision of adequate water capacity to supply fire protection systems and critical
process water.
 Isolate people from load carrying/mechanical handling systems, vehicle traffic and
storage and stacking locations.
 Provision and integrity of process tanks, waste holding tanks and bounded areas as
per relevant standards.
 It is recommended that all flammable areas and process area be maintained free of
ignition sources. Ensure that sources of ignition, such as pilot lights, electrical
ignition devices etc., at strategic locations like solvent storage areas are avoided.
 Strict hot work control and display of danger signs should be ensured.
 It is suggested to provide fire extinguishers in process plant at solvent storage area
and the vents of solvent tanks to be provided.
 It is suggested to have a periodical review of safety awareness and safety training
requirements of plant employees with respect to hazards present in the plant.
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3.1.10 Storage and Handling of Hazardous Chemicals

A storage and handling of hazardous chemical in a chemical industry is inevitable, land
they carry inherent characteristic risk to the employees due to the properties of chemicals
such as toxicity & flammability. Accident due to fire and explosion by flammable
substances are possible in process industry. The disastrous effect of fire, explosion and
release of toxic fumes in storage and production area, is due to inappropriate design,
improper storage, improper handling, poor maintenance or deficiencies in the operation of
the plant. Chemical in any form can be stored, handled and used if their physical,
chemical and hazardous properties are thoroughly understood and necessary precautions
are taken.
Chemicals are handled in standard containers like MS, HDPE, GI Drums, PVC Carboys,
etc. All the chemicals are to be arranged and stored in accordance with their
compatibility, dry, well ventilated, with flame proof electrical equipment and lighting.
All the chemicals are to be provided with identification labels. Eye wash/Drench shower
is to be provided at a strategic location for emergency purpose.
Chemical Safety Data Sheets and handling procedure, First Aid measures are to be
prepared and displayed for information and safety of the working personnel.
3.1.11 Action Plan for safe handling of Flammable and Toxic chemicals
Mitigation measures as provided in Table 3.12 will be followed /practiced during
transportation, unloading and handling of flammable and toxic chemicals, in order to
ensure health and safety of workers involved in handling hazardous chemicals and avoid
the human health impacts.
Table 3.12 Mitigation measures for safe handling of flammable and toxic chemicals
S.No. Activity Safety Precautions
1. Transportation of solvents like  Training will be provided to driver and cleaner
Toluene, IPA by road tanker regarding the safe driving, hazards of
Flammable chemicals, emergency handling
and use of SCBA sets.
 TREM card will be kept with Threshold Limit.
 SCBA set will be kept with TL.
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 Fire extinguishers will be kept with TL.

 Flame arrestor will be provided to TL exhaust.
 Instructions will be given not to stop road
tanker in populated area.
 Hazard Identification symbol and emergency
telephone number will be displayed as per
HAZCHEM CODE.
 Appropriate PPEs will be kept with TL.
 In case of leak or spill:
 Area will be isolated.
 Container shall be isolated.
 Source of leakage will be checked.
 Damaged containers or spilled material shall
not be attended without wearing appropriate
protective clothing.
 Leakage will be stopped, if possible to do so
without risk.
 Water spray will be used to reduce vapours
(but do not put water directly on leak, spill
area or inside container).
2. Unloading of solvents from tanker  Priority will be given for Tankers to
immediately enter the storage premises at site
and will not be kept waiting near the gate or
the main road.
 Security person will check License, TREM
CARD, Fire extinguisher condition; SCBA set
condition, Antidote Kit, required PPEs as per
SOP laid down.
 Store officer will take sample as per sampling
SOP from sampling point.
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 After approval of QC department unloading

procedure will be allowed be started.
 Following precautions will be taken during
unloading:
 Static earthling will be provided to road tanker.
 Tanker unloading procedure will be followed
according to check list and implemented.
 Only day time unloading will be permitted.
3. Solvents storage tanks safety  SS storage tank will be provided as per IS
code.
 Vent will be connected to water trap and vent
of water trap will be provided with flame
arrestor.
 FLP type pump & electric fittings will be
provided.
 Double static earthing will be provided to
storage tank, as per the requirement.
 Double Jumper clip will be provided to all
solvent handling pipeline flanges.
 Level transmitter will be provided with low
level/high level auto cut-off provision.
 Workers and Operators handling such
materials shall be trained for the hazards
(fire/explosion, health, chemical reactivity,
etc.) & safety measures
associated with them.
 NFPA label (hazard identification) along with
capacity of chemical will be displayed on
respective tanks & drums.
 Pipes and equipment shall be inspected at
Page 25
regular intervals.
 All storage areas shall be isolated from all
sources of open flame and well posted with
“Hazardous Chemical Storage”, “No
Smoking”, “Hot work Restricted” signs.
 Spark-resistant tools will be used.
 Water spray will be used to reduce vapours (by
taking care that water is not directed straight
away on leak, spill area or inside container).
 Combustibles (wood, paper, oil, etc.) will be
kept away from spilled material.
 Storage area will be provided with adequate
fire fighting/ extinguishing system, Fire
hydrant monitor with foam attachment facility,
etc.
4. Solvents transfer from storage  Double mechanical seal type FLP type pump
tank to Process Plant will be provided.
 Double on / off switch will be provided at tank
farm and process area near day tank. Pump
auto cut off with day tank high level will be
provided.
 Flame arrestor will be provided on day tank
vent.
 NRV will be provided on pump discharge line.
 Double static earthing will be provided to day
tank
Page 26
3.1.12 Fire Fighting System / Fire Control Plan

By looking to the hazardous nature of process and the chemicals that are handled and
processed, the chances of outbreak of fire cannot be totally ignored. Hence, to tackle such
a situation, company has developed well-resourced and adequate fire protection
system/firefighting network. The management provided the following facilities at site:
 Flame detectors, smoke/temperature actuated heat detectors with alarms, automatic
sprinkler system, installed at conspicuous locations as per the requirements.
 Preventive maintenance of firefighting facilities (Fire water pump, engines, hydrants,
monitors, alarm systems, etc.) shall be carried out periodically.
 Fire Water Tank of adequate capacity to combat the emergency, if arise
 Electric driven alarms & sirens will be placed at the conspicuous locations. Hand Bell
will be used in case of power failure.
 Working staff will be trained to operate DCP and CO2 extinguishers
3.1.13 Hazards/Exposure Control of Chemicals

The hazards involved and its control measures for the following chemicals which are
being handled / stored in the premises are given below:
I. METHANOL
Engineering controls:
Ignition control may be by nitrogen padding, natural gas padding, or by designation of a
hazard zone with ignition control. Because methanol is commonly stored with other
solvents and feed stocks, all piping and valves subject to carrying methanol should be
consistently labeled, and direction of flow should be indicated. All storage materials,
including totes and drums, require berming and adequate ventilation. Examples of
engineering controls that can be used to prevent exposure to methanol include:
 Installation of local ventilation hoods
 Ventilated enclosures around work processes (fume hoods, glove, boxes)
 Use of closed piping and storage systems
 Use of automatic systems to pump methanol from storage containers to process
systems or containers
Page 27
Provide exhaust ventilation or other engineering controls to keep the airborne

concentrations of vapors below their respective threshold limit value. Eyewash stations
and safety showers are proximal to the work-station location.
Respiratory protection:
Emergency Use: Self-contained breathing apparatus (SCBA) or positive pressure airline
with full face mask with escape pack should be worn in areas of a large release or
unknown concentration.
Eye Protection: Safety glasses for handling cylinders, Chemical goggles with full face
shield for connecting, disconnecting or opening cylinders.
Skin Protection: Chemical-resistant gloves for handling cylinders. Chemical resistant
outer garment should be worn when connecting or disconnecting cylinders. Total
encapsulating chemical suit may be necessary in large release area.
Other Protective Equipment: Safety shoes are recommended when handling cylinders.
Safety shower and eyewash fountain should be readily available.
Caution: Contact with eyes causes irritation, redness, pain and ingestion cause
Neurological, Gastro intestinal disorders.
II. SULPHURIC ACID

Engineering controls
Provide exhaust ventilation or other engineering controls to keep the airborne
concentrations of vapors below their respective threshold limit value. Ensure that eye
wash stations and safety showers are proximal to the work-station location. Store in
tightly closed containers in a cool, well ventilated area away from sunlight as it is react
with air and oxygen to form unstable peroxides that can explode. Metal containers
involving the transfer of Sulphuric Acid should be grounded and bonded.
Eye/face protection:
Safety goggles or glasses, and transparent face shield.
Skin protection:
Contact can irritate and burn the skin, prolonged and repetitive contact can cause skin
rash, dryness, itching and redness. Use of gloves and protective clothing can decrease the
harm to minimal.
Page 28
Respiratory Protection
Use NIOSH approved full piece respirator with an organic vapour cartridge. Increased
protection is obtained from full piece powdered air purifying respirators, or a self-
contained breathing apparatus should be available for emergency use. Use a supplied air
respirator for routine use.
Other/General Protection
Safety shoes, safety shower, eyewash "fountain".
3.2 DISASTER MANAGEMENT PLAN

A disaster is a catastrophic situation in which suddenly, people are plunged into
helplessness and suffering and, as a result, need protection, clothing, shelter, medical and
social care and other necessities of life.
Disasters can be divided into two main groups. In the first, are disasters resulting from
natural phenomena like earthquakes, volcanic eruptions, storm surges, cyclones, tropical
storms, floods, avalanches, landslides, forest fires. The second group includes disastrous
events occasioned by man, or by man's impact upon the environment. Examples are
armed conflict, industrial accidents, radiation accidents, factory fires, explosions and
escape of toxic gases or chemical substances, river pollution, mining or other structural
collapses, air, sea, rail and road transport accidents which can reach catastrophic
dimensions in terms of human loss.
There can be no set criteria for assessing the gravity of a disaster in the abstract since this
depends to a large extent on the physical, economic and social environment in which it
occurs. What would be consider a major disaster in a developing country, ill equipped to
cope with the problems involved, and may not mean more than a temporary emergency
elsewhere. However, all disasters bring in their wake similar consequences that call for
immediate action, whether at the local, national or international level, for the rescue and
relief of the victims. This includes the search for the dead and injured, medical and social
care, removal of the debris, the provision of temporary shelter for the homeless, food,
clothing and medical supplies, and the rapid re-establishment of essential services.
Page 29
3.2.1 Objectives of Disaster Management Plan

The Disaster Management Plan is aimed to ensure safety of life, protection of
environment, protection of installation, restoration of production and salvage
operations in this same order of priorities. For effective implementation of the Disaster
Management Plan, it should be widely circulated and personnel trained through
rehearsals/drills. The Disaster Management Plan should reflect the probable
consequential severalties of the undesired event due to deteriorating conditions or through
'Knock on' effects. Further the management should be able to demonstrate that their
assessment of the consequences uses good supporting evidence and is based on currently
available and reliable information, incident data from internal and external sources and if
necessary the reports of outside agencies. To tackle the consequences of a major
emergency inside the plant or in the immediate vicinity of the plant, a Disaster
Management Plan has to be formulated and this planned emergency document is called
"Disaster Management Plan".
The objective of the Industrial Disaster Management Plan is to make use of the combined
resources of the plant and the outside services to achieve the following:
 Effect the rescue and medical treatment of casualties;
 Safeguard other people;
 Minimize damage to property and the environment;
 Initially contain and ultimately bring the incident under control;
 Identify any dead;
 Provide for the needs of relatives;
 Provide authoritative information to the news media;
 Secure the safe rehabilitation of affected area; and
 Preserve relevant records and equipment for the subsequent inquiry into the cause and
circumstances of the Emergency.
In effect, it is to optimize operational efficiency to rescue, rehabilitate and render medical
help and to restore normalcy.
Page 30
Onsite Emergency Plan

An on-site emergency is caused by an accident that takes place in plant itself and the
effects are confined to the factory premises involving only the people working in the
factory. On-site emergency plan to deal with such eventualities is the responsibility of the
occupier and is mandatory. The preparation of an on-site emergency plan and furnishing
relevant information to the District Emergency Authority for the preparation of the off-
site emergency plan are statutory responsibilities of the occupier of every industry and
other units handling hazardous substances. An on-site emergency plan should contain the
following key elements:
 basis of the plan: Hazard analysis
 accident prevention procedure/measures;
 accident/emergency response procedure/measures and
 Recovery procedure.
3.2.2 Emergencies Identified

Spillage, pool fires are the possible emergencies in the pipelines, fire near storage, DG
set, and Transformers are the other possible emergencies.
The other emergencies are asphyxiation of persons, apart from risks due to cyclonic
conditions, earth quake, lightning, floods (natural calamities), sabotage, bombing (social
and other reasons) etc. which are not under the management control. Priority of protection
in the event of an emergency is; Life and safety of personnel, preservation of property,
restoration of normalcy.
3.2.3 Emergency Organization

Key personnel and essential employees are identified and are assigned emergency
responsibilities.
Security personnel, all operators, fitters, electricians etc. in the shifts are designated
essential employees. During emergencies, their services are drafted for essential
operations.
Page 31
3.2.4 Emergency Responsibilities

The responsibilities of the key personnel are appointed below:
Site Controller
On receiving information about emergency he would rush to Emergency Control Center
(ECC) and take charge of ECC and the situation. His responsibilities would be as
indicated below:
 Assesses the magnitude of the situation on the advice of Incident Controller and
decides;
o Whether the affected area needs to be evacuated;
o Whether personnel who are at assembly points need to be evacuated;
 Declares Emergency and orders for operation of emergency siren;
 Organizes announcement by public address system about location of emergency;
 Assesses which areas are likely to be affected, or need to be evacuated or are to be
alerted;
 Maintains a continuous review of possible development and assesses the situation in
consultation with Incident Controller and other Key Personnel as to whether shutting
down the plant or any section of the plant is required and if evacuation of persons is
required;
 Directs personnel for rescue, rehabilitation, transport, fire, brigade, medical and other
designated mutual support systems locally available, for meeting emergencies;
 Controls evacuation of affected areas, if the situation is likely to go out of control or
effects are likely to go beyond the premises of the factory, informs the District
Emergency Authority, Police, Hospital and seeks their intervention and help;
 Informs Inspector of Factories, Deputy Chief Inspector of Factories, RPCB and other
statutory authorities;
 Gives a public statement if necessary;
 Keeps record of chronological events and prepares an investigation report and
preserves evidence; and
 On completion of On Site Emergency and restoration of normalcy, declares all clear
and orders for all clear warning.
Page 32
Incident Controller
 Assembles the incident control team;
 Directs operations within the affected areas with the priorities for safety to personnel
minimize damage to the plant, property and environment and minimize the loss of
materials;
 Directs the shutting down and evacuation of plant and areas likely to be adversely
affected by the emergency;
 Ensures that key personnel help is sought;
 Provides advice and information to the Fire and Security Officer and the Local Fire
Services as and when they arrive;
 Ensures that all non-essential workers/staff of the affected areas are evacuated to the
appropriate assembly points, and the areas are searched for casualties;
 Has regard to the need for preservation of evidence so as to facilitate any inquiry into
the causes and circumstances, which caused or escalated the emergency;
 Co-ordinates with emergency services at the site;
 Provides tools and safety equipment to the team members;
 Keeps in touch with the team and advices them regarding the method of control to be
used; and
 Keeps the Site Controller of Emergency informed of the progress being made.
Emergency Coordinator – Rescue, Fire Fighting

On knowing about emergency, rushes to ECC;
 Helps the Incident Controller in containment of the emergency;
 Ensure fire pumps are in operating condition and instructs pump house operator to
ready for any emergency with standby arrangement;
 Guides the fire fighting crew i.e. firemen, trained plant personnel and security staff;
 Organizes shifting the fire fighting facilities to the emergency site, if required;
 Takes guidance of the Incident Controller for firefighting as well as assesses the
requirements of outside help;
 Arranges to control the traffic at the gate and the incident area;
Page 33
 Directs the security staff to the incident site to take part in the emergency operations
under his guidance and supervision;
 Evacuates the people in the plant or in the nearby areas as advised by Site Controller;
 Searches for casualties and arranges proper aid for them;
 Assembles search and evacuation team;
 Arranges for safety equipment for the members of this team;
 Decides which paths the evacuated workers should follow; and
 Maintains law and order in the area, and if necessary seeks the help of police.
Emergency Coordinator – Medical, Mutual Aid, Rehabilitation, Transport and

Communication
 In the event of failure of electric supply and thereby internal telephone, sets up
communication point and establishes contact with the ECC;
 Organizes medical treatment to the injured and if necessary will shift the injured to
nearby hospitals;
 Mobilizes extra medical help from outside, if necessary;
 Keeps a list of qualified first aid providers for the plant and seeks their assistance;
 Maintains first aid and medical emergency requirements;
 Makes sure that all safety equipment is made available to the emergency team;
 Assists Site Controller with necessary data to coordinate the emergency activities;
 Assists Site Controller in updating emergency plan, organizing mock drills,
verification of inventory of emergency facilities and furnishing report to Site
Controller;
 Maintains liaison with Civil Administration;
 Ensures availability of canteen facilities and maintenance of rehabilitation center.
 Liaises with Site Controller/Incident Controller;
 Ensures transportation facility;
 Ensures availability of necessary cash for rescue/rehabilitation and emergency
expenditure;
 Controls rehabilitation of affected areas on discontinuation of emergency; and
 Makes available diesel/petrol for transport vehicles engaged in emergency operation.
Page 34
Emergency Coordinator – Essential Services

 Assists Site Controller and Incident Controller;
 Maintains essential services like Diesel Generator, Water, Fire Water, Compressed
Air/Instrument Air, power supply for lighting;
 Plans alternate facilities in the event of power failure, to maintain essential services
such as lighting, etc.
 Organizes separate electrical connections for all utilities and emergency services so
that in the event of emergency or fires, essential services and utilities are not affected;
 Gives necessary instructions regarding emergency electrical supply, isolation of
certain sections etc. to shift in-charge and electricians; and
 Ensures availability of adequate quantities of protective equipment and other
emergency materials, spares etc.
3.2.5 Emergency Facilities

Assembly Point
In affected & vulnerable plants, all non essential workers (who are not assigned any
emergency duty) will be evacuated from the area & they shall report to specified
Assembly Points. Assembly Points shall be marked at a safe place well away from area of
risk and least affected by the down wind direction.
To ensure that workers do not have to approach the affected area to reach the Assembly
Point, proper location and number shall be marked at Assembly Points. Each Assembly
Point shall be manned by a nominated person to record the names and dept. At each
Assembly Point, duties of Assembly Point In-charge shall be displayed in brief. Before
reaching an Assembly Point or subsequently, if it is required to pass through an affected
area or due to presence of toxic substances, suitable PPE's including respirators, helmet
etc., shall be issued & made available with workers.
Emergency Control Center (ECC)
It is a location where all key personnel like Chief Coordinator, Emergency controller,
maintenance coordinator can assemble and monitor aspects related to emergency and take
decisions related to emergency. The office room is designated as ECC. In case if this area
is affected, zone security room is designated as alternative ECC.
Page 35
Telephone and other facilities required with necessary documents shall be displayed in
ECC for ready reference. Designated trained personnel shall operate ECC. In case of
Major Emergency, the Site Main Controller will operate from ECC.
Fire Control Arrangements

Role of Manager (Fire and Safety)/Shift In-Charge (Fire & Safety)
 Incident Controller shall direct the firefighting and Emergency operation. His duties
include:
 Keep the constant touch with the SMC/In-charge - EHS.
 Direct the crew members to the scene of emergency and arrange replenishment of
Manpower/equipment/extinguishing media etc.
Role of EHS Representative:
 On being notified about the location of fire/ gas leakage, he shall immediately
proceeds to the help.
 Decides his line of action in consultation with Incident controller and takes
appropriate measures to handle the emergency.
 Shall assess the severity of the incident & shall immediately report to emergency
controller about the gravity of the situation.
 He shall also assess the extra requirement required if any, from the neighboring
industry.
Medical Arrangement
The roles of Medical officers are as follows:
 He will report immediately to the SMC/IC.
 He will render necessary treatment, at Occupational Health Center.
 He will arrange for Hospitalization and Treatment at outside hospitals, if required.
 He will mobilize in getting the services of External medical agencies, other Para –
medical services etc. and transportation services etc.
 He will arrange for extra medical assistance/antidotes, from out, if required.
 He will arrange for first-aid trained volunteers for necessary help.
Page 36
 He will liaise with the Government Health Authorities for treatment of the affected
persons nearby
Communication System
Communication System is a Crucial Factor while handling emergency. Company has
quick & effective Communication System through which, any situation, which can lead
to emergency, can be informed or known to
a) All persons working inside the plant.
b) Key Personnel outside during normal working hours & during off-duty hours.
c) Outside emergency services, Statutory and Local Authorities &
d) Neighboring facilities and public leaving in vicinity.
Each and every section, Plant & Department of the Factory will be connected by internal
telephones with SMC, Supervisor or IC‟s. External Phone at Office and Residence and
Mobile shall also be made available with Key Personnel and top executive of the factory.
The Communication System shall begin with raising the alarm declaring the emergency,
Telephone messages and Procedure to communicate the emergency to other persons &
General Public.
Raising the Alarm

As soon as incident takes place inside the factory and is noticed by someone, the first step
shall be to raise the nearest manual emergency bell to alert the nearby people. Next,
he/she shall inform the security persons to raise the emergency siren located at the factory
gate. The security personnel sound the siren.
3.2.6 Off-Site Emergency Plan

If an accident takes place in a plant and its effects are felt outside its premises, the
situation thus created is called an “off-site” emergency. It no longer remains the concern
of the factory management alone but also becomes a concern for the general public living
outside or passing by the premises of the factory or storage site involved. To meet such
situations, off-site emergency plans are to be prepared as stipulated and put into
operation.
Page 37
It is mandatory under Rule 16 of the Hazardous Chemical Rules for District authorities to
prepare an off-site emergency plan in respect of clusters of hazardous chemical industries
or at locations where accidents are likely to have an off-site adverse effect.
The off-site emergency plan should detail how emergency related to major accidents on
the site will be dealt with. For preparing the plan, the concerned district authorities should
consult the industries and other persons who would be concerned with its execution
should such an emergency arises
Responsibility for Planning an Off-Site Emergency

The planning for emergency response requires cooperation among the responders to know
the persons responsible for various activities. This understanding is facilitated through
personal interaction and close working in devising and updating a plan. Therefore, the
pre-requisite for preparing a plan is the formation of a planning team. The possible
composition of the planning team is given below:
Planning Team-Members
 Collector/Deputy Collector
 District authorities In-charge of Fire Services, Police
 Medical Services
 Factory Inspectorate
 Pollution Control Board
 Industries and
 Transport
Aspects Proposed to be considered in the Off-Site Emergency Plan

The main aspects, which should be included in the emergency plan, are:
Organization
Detail of command structure, warning systems, implementation procedures, emergency
control centers. Names and appointments of incident controller, site main controller, their
deputies and other key personnel.
Communications
Identification of personnel involved, communication center, call signs, network, list of
telephone numbers.
Page 38
Specialized Knowledge
Details of specialist bodies, firms and people upon whom it may be necessary to call
e.g. those with specialized fuel knowledge, laboratories.
Voluntary Organizations
Details of organizers, telephone numbers, resources etc.
Fuel Information
Details of the hazardous substances stored and a summary of the risk associated with
them.
Meteorological Information
Arrangements for obtaining details of weather forecasts and weather conditions
prevailing at that time.
Humanitarian Arrangements
Transport, evacuation centers, emergency feeding, treatment of injured, first aid,
ambulances and temporary mortuaries.
Public Information
Arrangements for
 dealing with the media press office;
 Informing relatives, etc.
Assessment of Emergency Plan

Arrangements for:
 Collecting information on the causes of the emergency;
 Reviewing the efficiency and effectiveness of all aspects of the emergency
plan.
Role of the Emergency coordinating Officer

The various emergency services would be coordinated by an emergency coordinating
officer (ECO), who will be designated by the district collector. The ECO would liaison
closely with the site main controller. Again depending on local arrangements, for very
severe incidents with major or prolonged off-site consequences, the external control
would be passed to a senior local authority administrator or even an administrator
Page 39
appointed by the central or state government. The ECO will be equipped with address and
phone numbers of important agencies.
Role of the Local Authority

The duty to prepare the off-site plan lies with the local authorities. The emergency
planning officer (EPO) appointed should carry out his duty in preparing for a whole range
of different emergencies within the local authority area. The EPO should liaison with the
plant, to obtain the information to provide the basis for the plan. This liaison should
ensure that the plan is continually kept up to date.
It will be the responsibility of the EPO to ensure that all those organizations which will be
involved off site in handling the emergency, know of their role and are able to accept it
by having for example, sufficient staff and appropriate equipment to cover their particular
responsibilities. Rehearsals for off-site plans should be organized by the EPO.
Role of Police
Formal duties of the police during an emergency include protecting life and property and
controlling traffic movements.
Their functions should include controlling bystanders, evacuating the public, identifying
the dead and dealing with casualties, and informing relatives of death or injury.
Role of Fire Authorities

The control of a fire should be normally the responsibility of the senior fire brigade
officer who would take over the handling of the fire from the site incident controller on
arrival at the site. The senior fire brigade officer should also have a similar responsibility
for other events, such as explosions. Fire authorities in the region should be apprised
about the location of all stores of flammable materials, water and foam supply points, and
firefighting equipment. They should be involved in on-site emergency rehearsals both as
participants and, on occasion, as observers of exercises involving only site personnel.
Page 40
Role of Health Authorities

Health authorities, including doctors, surgeons, hospitals, ambulances, and so on, should
have a vital part to play following a major accident, and they should form an integral part
of the emergency plan.
For major fires, injuries should be the result of the effects of thermal radiation to a
varying degree, and the knowledge and experience to handle this in all but extreme cases
may be generally available in most hospitals. Major off-site incidents are likely to require
medical equipment and facilities additional to those available locally, and a medical
"mutual aid” scheme should exist to enable the assistance of neighboring authorities to be
obtained in the event of an emergency.
3.2.7 Occupational Health & Safety Programme

M/s. Regal Plywood Industries Pvt. Ltd. has prepared the Occupational Health
Surveillance Programme which shall be followed right from the project construction &
erection phase and the same shall be updated for the upcoming new facility, if required.
The details of the same are described in the following sections.
Hospital Facilities /Factory Medical Officer & OHC
 Company shall made formal agreements with nearby hospitals having facilities to
attend fire and toxic effect cases, emergency cases, attending the affected persons
in the emergency arising out of accidents, if any, etc.
 All types of first aid related accessories, Medicines & Antidotes as prescribed by
FMO, etc. shall be made available at conspicuous locations.
Ambulance Van & First Aid Box
 An Emergency Vehicle shall be made available round the clock to be used as an
Ambulance during emergency.
 First Aid Boxes will be made available at the different location in the plant. Training
shall be given to employees for First Aid.
Plan for Periodic Medical Checkup
 Periodic Medical Examination shall be conducted as per the following schedule;
 Workers employed will be examined by a Qualified Medical Practitioner/ Factory
Medical.
Page 41
3.2.8 Safety Trainings & Mock Drills

Safety trainings (on Safe Material Handling, First Aid, & all Safety Aspects) shall be
provided every 15 days by the Safety Officers with the assistance of faculty members
called from other Professional Safety Institutions and Universities. In addition to regular
employees, limited contractor labors will also be given safety training. To create safety
awareness, safety films shall be shown to workers and leaflets shall be distributed.
Mock Drills
 To evaluate the effectiveness of emergency preparedness and to spread the
awareness among employees mock drill will be carried out at the interval of every six
months.
 After completion of the mock drill, summary report shall be made and corrections
will be done if any weakness has been observed.
Frequency of Mock Drills

 On-site emergency: Once every 6 months
 Off-site emergency: Once every year.
Page 42
Fig 3.6 Site plan
Page 43

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M/s. SOLID PLY (P) LTD.

PROPOSAL FOR RESIN MANUFACTURING PLANT

M/s. REGAL PLYWOOD INDUSTRIES PVT.

Proposed Capacity: Manufacture of Resins with 3.5 Tons/day

Existing Capacity: Plywood – 350 TPM and Veneer – 500 TPM

Sector : 21 - 5(f) – Synthetic organic chemicals industry (dyes &

The industry has obtained CFO vide Order No. 7294/APPCB/ZO-

1.1 NEED OF THE PROJECT:

1.2 BRIEF DESCRIPTION OF NATURE, SIZE, LOCATION OF THE PROJECT

Fig 1: Google map around 10 km radius

Fig 2: Topo map around 10 km radius

Table 2: Salient features of the project

13. National parks Kambalakonda Wildlife Sanctuary – 4.13 km SW

1.3 LAND AREA BREAK-UP

2.0 EXISTING PRODUCTION DETAILS AS PER CFO ORDER:

PROPOSED PRODUCTION DETAILS:

EXISTING RAW MATERIAL DETAILS:

PROPOSED RAW MATERIAL DETAILS:

3.0 MANUFACTURING PROCESS:

Plywood process flow diagram

3.2 Proposed Resin Plant Manufacturing Process:

Process Flow Diagram:

Phenol 340 kgs

Phenol Formaldehyde Resin (Double Stage):

ONE TON BASIS

Melamine Formaldehyde Resin:

Process Flow Diagram:

ONE TON BASIS

Urea Formaldehyde Resin:

Process Flow Diagram:

ONE TON BASIS

Melamine Urea Formaldehyde Resin:

ONE TON BASIS

4.0 UTILITIES, RESOURCE REQUIREMENTS AND ASSOCIATEDFACILITIES

Table 5: Fresh water requirement for Proposed:

Table 6: Waste water generation for existing:

Table 7: Waste water generation for Proposed:

Table 8: Effluent characteristics before and after treatment

2 TSS (mg/l) 500-700

3 TDS (mg/l) 4000-6000

4 COD (mg/l) 11000-13000

5 BOD (mg/l) 5000-6500

4.2 RAINWATER HARVESTING AND STORM WATER MANAGEMENT

4.3 AIR QUALITY MANAGEMENT

3 Fuel Furnace Oil HSD HSD

4 Control Equip- Bag Filter Acoustic Enclo- Acoustic En-

4.3.1 Fugitive emissions:

Table 9: Manpower Requirement

4.5 NOISE QUALITY MANAGEMENT

4.6 SOLID WASTE MANAGEMENT

2. Carboys -- 100 Nos/annum APPCB authorized agencies

3. Drums -- 50 Nos/annum APPCB authorized agencies

4.6.1 Mitigation Measures for Impacts on Environment during Construction Phase

Attributes Impacts causing fac- Mitigative Measures

Water  water discharge from  Good construction practices will be

Socio- Expectations/aspirations Assessing local skills availability & the skills

Ecology  Loss/degradation of  Avoid flowering season for site activities

4.6.2 Mitigation Measures for Impacts on Environment during Operation Phase

Attributes Impacts causing fac- Mitigative Measures

Air  PM, SO2, NO2, CO emissions  Tarpaulin covered vehicles.

Water Run off:

Socio‐  Health issues among nearby  Specific control measures for

Injuries from equipment Occupational health & safety