20150620 EIA Final

SHRIRAM RAYONS (A UNIT OF DCM SHRIRAM INDUSTRIES LTD.)

EIA FOR EXPANSION OF EXISTING PLANT ADDITIONAL STUDIES

KADAM ENVIRONMENTAL CONSULTANTS | JUNE 2015 216

7 ADDITIONAL STUDIES

7.1 Public Hearing

As per circular dated 10th December 2014, public hearing is exempted for projects or activities or units located within the Industrial Estates or Parks, which were notified prior to 14th September 2006. The PH waiver is granted by EAC committee during presentation dated 18th February 2015. MoEF has waved off Public Hearing vide MoM of meeting held on 18th February, 2015 on their website on 18thMarch, 2015.

7.2 Risk Assessment

The risk assessment process is intended to identify existing and probable hazards in all operations and work environment, to quantify the hazards and to access the risk levels of those hazards in order to prioritize those that need an immediate attention.

7.2.1 Methodology of Risk Assessment

The methodology includes,

1. Hazard identification, 2. Selection of potential loss scenarios, 3. Simulation of release source model on DNV’s PHAST 7.1, 4. Plotting the damage contour on site map

These steps undertaken to carry out risk assessment for this project are described in following sections.

7.2.2 Hazard Identification

The project description, and other project related data provided by the client have been comprehensively reviewed to identify the hazardous operations. Also the information on the hazardous properties (MSDS) of all the chemicals handled at the site has been reviewed to identify the hazards associated with the same.

At present SR is going to expand its capacity at existing facility.No new raw materials & chemicals will be used. Storage of some of the raw material at the site can lead to uncontrolled release of hazardous material causing hazard. On the basis of this, the important hazards that can lead to accident in the proposed expansion project are described in Table 7-1.

Table 7-1: Important Hazardous Events Type of Event Explanation

BLEVE Boiling Liquid Evaporating Vapor Explosion; may happen due to catastrophic failure

of refrigerated or pressurized gases or liquids stored above their boiling points, followed by early ignition of the same, typically leading to a fire ball

Deflagration Is the same as detonation but with reaction occurring at less than sonic velocity and

initiation of the reaction at lower energy levels

Detonation A propagating chemical reaction of a substance in which the reaction front advances in the unreacted substance at or greater than sonic velocity in the unreacted material

Explosion A release of large amount of energy that form a blast wave

Fire Fire

Fireball

The burning of a flammable gas cloud on being immediately ignited at the edge

before forming a flammable/explosive mixture.




Type of Event Explanation

Flash Fire A flammable gas release gets ignited at the farthest edge resulting in flash-back fire

Jet Fire A jet fire occurs when flammable gas releases from the pipeline (or hole) and the

released gas ignites immediately. Damage distance depends on the operating pressure and the diameter of the hole or opening flow rate.

Pool Fire Pool fire is a turbulent diffusion fire burning above a horizontal pool of vaporizing

hydrocarbon fuel, where the fuel has zero or low initial momentum

Spill Release ‘Loss of containment’. Release of fluid or gas to the surroundings from unit’s own

equipment / tanks causing (potential) pollution and / or risk of explosion and / or fire

Structural Damage Breakage or fatigue failures (mostly failures caused by weather but not necessarily)

of structural support and direct structural failures

Vapor Cloud Explosion

Explosion resulting from vapor clouds formed from flashing liquids or non-flashing liquids and gases

Hazard and Damage Assessment

Toxic, flammable and explosive substances released from sources of storage as a result of failures or catastrophes, can cause losses in the surrounding area in the form of:

Toxic gas dispersion, resulting in toxic levels in ambient air, Fires, fireballs, and flash back fires, resulting in a heat wave (radiation), or Explosions (Vapours Cloud Explosions) resulting in blast waves (overpressure).

Consequences of Fire/Heat Wave

The effect of thermal radiation on people is mainly a function of intensity of radiation and exposure time. The effect is expressed in term of the probability of death and different degree of burn. The consequence effects studied to assess the impact of the events on the receptors are provided in Table 7-2.

Table 7-2 : Damage due to Radiation Intensity Radiation (kW/m2) Damage to Equipment Damage to People

4.0 - Causes pain if duration is longer than 20 sec.

But blistering is unlikely.

12.5 Minimum energy to ignite wood

with a flame; melts plastic tubing.

1% lethality in one minute. First degree burns in 10 sec.

37.5 Severe damage to plant

100% lethality in 1 min.

50% lethality in 20 sec.

1% lethality in 10 sec.

Consequences of Overpressure

The effects of the shock wave vary depending on the characteristics of the material, the quantity involved and the degree of confinement of the vapor cloud. The pressure of the shock wave decreases rapidly with the increase in distance from the source of the explosion. The overpressure damage is shown in Table 7-3.

Table 7-3: Overpressure Damage Overpressure bar Damage

1 Fatality

0.41 Ear Drum Rupture to humans

0.2 Structural Damage to buildings




Overpressure bar Damage

0.03 Glass Damage

Reference: World Bank Technical Paper no. 55- Technical Ltd. for assessing hazards- A manual

Consequences of Toxic Release

The effect of exposure to toxic substance depends upon the duration of exposure and the concentration of the toxic substance.

Short-term exposures to high concentration give Acute Effects while long term exposures to low concentrations result in Chronic Effects.

Only acute effects are considered under hazard analysis, since they are likely credible scenarios. These effects are:

Irritation (respiratory system, skin, eyes) Narcosis (nervous system) Asphyxiation (oxygen deficiency) System damage (blood organs)

Following are some of the common terms used to express toxicity of materials.

Threshold Limit Value (TLV): It is the permitted level of exposure for a given period on a weighted average basis(usually 8 hr/day, 40h/week)

Short Time Exposure Limit (STEL): It is the permitted short term exposure limit usually for a 15 minutes exposure.

Immediately Dangerous to life and health (IDLH): It represents the maximum concentration of a chemical from which, in the event of respiratory failure, one could escape within 30 minutes without a respirator and without experiencing any escape/impairing (e.g. Severe irritation) or irreversible health effects.

Lethal Concentration Low (LCLo): It is the lowest concentration of a material in air, other than LC50, which has been reported to cause a death in human or animals.

Toxic Concentration Low (TCLo): It is the lowest concentration of a material in air, to which humans or animals have been exposed for any given period of time that has produced a toxic effects in humans or produced carcinogenic, neoplastigenic or tetratogenic effect in humans or animals.

Emergency Response Planning Guidelines1 (EPRG1): The maximum airborne concentration below which it is believed that nearly all individuals could be exposed for up to 1 hour (without a respirator) without experiencing other than mild transient adverse health effects or without perceiving a clearly defined objectionable odor.

Emergency Response Planning Guidelines2 (ERPG2): The maximum airborne concentration below which it is believed that nearly all individuals could be exposed for up to 1 hour without experiencing or developing irreversible or other serious health effects or symptoms that could impair their abilities to take protective action.

Emergency Response Planning Guidelines3 (ERPG3): The maximum airborne concentration below which it is believed that nearly all individuals could be exposed for up to 1 hour without experiencing or developing life-threatening health effects.

7.2.3 Selection of Maximum Credible Loss Scenarios (MCLs’)

Following important points should be considered for the selection of release scenarios.




Flammability and the flash point of the material Phase of material i.e. liquid or gas Threshold quantity of the chemicals as prescribed in MSHIC Rule Operating temperature and pressure of the material Total inventory of the material

On the basis of study of chemical properties (MSDS) of the chemicals those are selected for simulations are presented inTable 7-4.

Table 7-4: Chemicals selected for Simulation

S. N

o

Nam

e

Stat

e

B. P

. °C

F. P

. °C

LEL,

U

EL%

TLV

ppm

Sp. G

r.

(H2O

=1)

Vap

. Den

. (a

ir=

1)

Odo

ur

Thre

shol

d pp

m o

r m

g/l

IDLH

ERP

G 1

, 2,

3

1 Carbon

Di-sulphide

Liquid 46.3 Closed Cup -30°C

1.3 50

10 1.2632 2.63 0.1 500 1, 50, 500

LD50mg/kg, LC50mg/m3: The LC50 values hereunder are estimated on the basis of a 4-hour exposure. Acute oraltoxicity (LD50): 2780 mg/kg [Mouse]. Acute toxicity of the vapor (LC50): 12500 ppm 4 hour(s) [Rat].

On the basis of the information provided in Table 7-4, and as discussed over failures sceneries given in publications like World Bank Technical Paper 55 and TNO Purple Book and the experience of the consultant, MCLs’ which may take place are presented in Table 7-5.

Table 7-5: Scenarios Selected for Simulation

S. No.

Full name of the Raw Material

Hazard involved

No. of Container & Size at Site Types of Failure

Possible Consequences

Studied Nos. Capacity

1 Carbon di-sulphide

Flammable & Toxic

6 40 m3 each

25 mm leak

Jet Fire Early Pool Fire

Late Pool Fire

Late Ignition

Toxic Release

2 6.5 m3 each

1 8 m3 each

Table 7-6: Safety Measures for Storage of Carbon di-sulphide Raw Materials/ Product CS2

Mode of Storage Metallic Tanks

Capacity of Means of Storage 300 MT Max 26 MT

No. of Means of Storage 6 Tanks 3 Tanks

Total Capacity (m3) 240 21

Flash Point (°C) -30

IDLH (ppm) 500

Storage Capacity of Vessel (m3) 6 of 40 m3

each 2 of 6.5 m3 each and

1 of 8.0 m3

Dimension of tank

Height (m) 8.311 3.5

Dia. (m) 2.504 1.524

Volume of Dyke (m3) 705.64 120

Storage Type Above Ground Above Ground

MOC MS MS




safety measures

Overfill protection High level/Overflow

Alarm Stored under water

Emergency vent on the tanks for

Pressure Safety Yes

Remote level monitoring

N/A

Vapour emission control

Open to Atmosphere& stored under water

Blanketing Water Blanket inside the tank above CS2 level

Temperature control provision

Water Sprinklers available to keep the tank Cool. Generally tanks are kept submerged in

water inside dyke

CS2 kept under water.

Fire fighting provision

Hydrant points & Portable foam monitors available

7.2.4 Simulation of Release and Development of Contours

As the MCLS’ were developed for the selected set of chemicals, the next step is to carry out the consequence analysis. The consequence analysis results along with their contours are presented in the following sections.

Carbon di-sulphide (CS2)

Radiation level and effect distance due to the release of CS2 are presented in Table 7-7, whereas the overpressure effect distance and toxic effect distance are given inTable 7-8&Table 7-9.

Table 7-7: Radiation Level and Effect Distance due to Release of CS2

Chemical Failure

Scenarios Consequence

Met. Data

Effect Distance in Meters to Radiation Level

4 kW/ m2 12.5 kW/ m2 37.5 kW/ m2

Carbon di-sulphide

25 mm Leak

Jet Fire

1.5/F 22.30 18.26 NR

3.0/D 21.48 17.75 NR

5.0/D 20.35 16.77 14.32

Early Pool Fire

1.5/F 20.21 10.51 6.85

3.0/D 21.29 11.39 6.79

5.0/D 21.99 12.57 6.91

Late Pool Fire

1.5/F 32.26 17.57 9.46

3.0/D 32.43 18.68 9.10

5.0/D 33.09 20.66 9.14

Table 7-8: Overpressure Effect Distance due to Release of CS2

Chemical Failure

Scenarios Consequence Met. Data

Overpressure Distance in Meters 0.02 bar 0.06 bar 0.2 bar

Carbon di-sulphide

25 mm Leak Late Ignition 1.5/F 105.56 66.94 53.14 3.0/D 85.92 58.87 49.20 5.0/D 59.86 42.27 35.98

Table 7-9: Effect Distance for Toxic Dose due to Release of CS2

Chemical Failure

Scenarios Met. Data

Effect Distance in Meters to Toxic Dose (in ppm)ERPG 1 (1) ERPG 2 (50) ERPG 3 (500)

Carbon di-sulphide

25 mm Leak 1.5/F 9032.01 676.65 90.32 3.0/D 1793.65 186.24 52.42




Chemical Failure

Scenarios Met. Data

Effect Distance in Meters to Toxic Dose (in ppm)ERPG 1 (1) ERPG 2 (50) ERPG 3 (500)

5.0/D 1366.06 143.42 43.36

Figure 7-1: Late Pool Fire Effect Contour due to 25mm Leak in CS2 Tank at Weather 3.0/D

Figure 7-2: Late Explosion- Overpressure Effect Distance for CS2 Tank at Weather 3.0/D




Figure 7-3: Maximum Concentration- Toxic Effect Distance of CS2 at 3.0/D

7.2.5 Safety Measures for CS2

Storage and Handling of Carbon Di-sulphide (CS2)

Storage

Due to high vapour pressure of CS2, bulk storage is always under water and at or below atmospheric temperature. Tanks are sprayed with water in hot weather to keep the temperature low and the vapour pressure down.

Following points are considered for storage of CS2;

Structures in which CS2 is stored is non-combustible and either open type or well ventilated at floor level.

Buildings for the storage of CS2 is isolated from other operations and buildings. CS2 vapour is 2.63 times heavy as air, therefore, special down draft or lateral type ventilation

has to provide for room where CS2 is stored or used. Although the threshold limit value for CS2 is accepted as 10 ppm, the concentration of CS2 vapour in the work room should be maintained below 10 ppm. Care is taken to ensure that the same air is not recirculated in the room and the vapour is drawn away from the operators’ faces. The ventilators of CS2 storage rooms should be fitted with two layers of the fine wire mesh of non-corroding metal.

All CS2 tanks, pipelines, etc. is connected by copper or aluminium strips and is earthed to prevent fire due to static electricity.

Only flameproof motors are installed in the areas where CS2 is stored or used. Thermal cut-outs, switches, relays, transformers, etc, are not installed in these area.

All electrical lights, fittings and other electrical equipment, such as portable electrical hand lamps and tools, electric clocks, receptacles, panel boards used in the room where CS2 is stored or used, are flameproof.




CS2 is stored in cylindrical tanks with dished ends. The tanks may be erected either vertically or horizontally. The CS2 is stored always under water in storage tanks. CS2 is not filled in any vessel in excess of 85% of its capacity and 15% of tank volume is filled with water. However, this will not apply to cases where CS2 is stored in small containers of less than 250 litres capacity, provided such containers are provided with a vent pipe that is taken out of the building and the outlet is fitted with suitable flame arrester.

Tanks used for storage of CS2 or the equipment in which CS2 is used, should be kept properly closed and its inlet and out let valves properly tightened in closed position when these tanks are kept filled with water or inert gas.

CS2 is stored in containers not exceeding 250 litres capacity, it is not necessary to keep the container surrounded by a dike. No indoor storage tank have a capacity exceeding 750 litres and the combined storage capacity of indoor storage tanks are not to exceed 1500 litres.

Any installation of storage tanks exceeding 1500 litres are of outdoor type with adequate clear distance between the installation& other buildings.

Where any indoor or outdoor storage installation of CS2 exceeds 1000 litres storage capacity, storage tanks are surrounded by a dyke, the total capacity of which is at least equal to the combined capacity of the tanks in it, plus 15 cm of height up to the bottom of dyke overflow. The dike has to be kept filled with water and the overflow is sewered to a safe palace. The water drain of the dike is kept closed with a blind flange or valve which should be located outside or be capable of operation from outside.

Handling

Liquid CS2 is never pumped. Air pressure is not applied to containers of CS2 because of the development of an explosive mixture. The chemical is expelled from tank, drum or any other container by displacement with water pressure or inert gas pressure.

Only non-sparking, non- ferrous tools are used in areas where CS2 is stored or used.Any heavy blows are not struck where CS2 vapours are likely to be present.

Locomotives, boilers or diesel engines are not permitted within 30 metres of the area around CS2 storage tanks or usage points.

People handling CS2 or working close to the storage or usage spots should wear rubber shoes or other shoes having sole fastened by sewing with string and not nails.

Drains provided for draining water, process fluids, etc, out of the plants using CS2 is closed drains or suitably covered trenches with adequate traps or sumps provided in the drains for trapping CS2 carried over with the water or process fluid or process effluent. These traps are checked for CS2 contents which, if found, are removed immediately and transferred to safe storage places.

Mild steel or alloy steel pipes are used for transferring CS2. All CS2 pipes above 25 mm diameter have flanged joints. For long runs of pipe lines, there are

minimum numbers of flanged joints to minimize chance of leakage. Screwed joints are avoided. All outdoor CS2 pipelines are lagged suitably.

Lagged or unlagged steam lines or any other hot fluid carrying lines which may produce surface temperature of 90 °C is not permitted in the area situated within a radius of 15 meters around CS2 storage tanks or usage point.

Preventive Measures for CS2

Operation in which CS2 is used should be completely enclosed both because of its high toxicity and fire hazard.

Persons who are likely to get exposed to unknown concentrations of CS2 vapours should wear special type of personal protective equipment, such as canister type gas mask, self-




containedbreathing equipment, safety belt, etc. requirement of which may be assessed according to the prevailing working conditions.

A readily accessible, well- marked safety shower, controlled by quick opening valve, is located in each area where CS2 is handled; small hose line connected to a clean water line and bubbler drinking fountain for washing the eyes is also be provided.

Smoking & carrying out of hot job involving heating, open flame or spark is prohibited in the area situated within a radius of 15 meters around the place of bulk storage or usage of CS2 and suitable sign board indicating ‘Highly flammable, No naked flame- No spark- No smoking- No welding zone’ is conspicuously exhibited in these areas.

The job involving use of welding and gas cutting sets & blow lamps in the prohibited area may be carried out under the supervision of a trained & responsible person after taking all the adequate safety precautions and after obtaining the necessary authorization from the fire or safety officer.

Spills and Leakage of CS2

Cordon& clear the area. Post warning signs, and controllers provided with adequate personal protective equipment. Keep all sources of ignition away. Allow the spilled CS2 to evaporate. Steps should be taken to ventilate the area as quickly as possible.

If spilled or splashed on the body, remove immediately any clothing, gloves or shoes soaked with CS2 and wash the body thoroughly.

Photographs of existing storage tanks at site is given below;

Photographs 7-1: Photographs of CS2 Storage Tanks

7.3 Disaster Management Plan

7.3.1 About Industrial Activities

Site

Details about site are provided in Chapter 1, Section 1.3.3.

Manufacturing Process

Manufacturing process of various products are described in Chapter 2, Section 2.5.

Persons Working

The Factory runs continuously in three shifts of 8 hrs each.

A - Shift 07.00 - 15.00 hrs,




B - Shift 15.00 - 23.00 hrs,

C - Shift 23.00 - 07.00 hrs

General shift is from 07.45 to 16.15 hrs. for technical, production and engineering persons.

While commercial and general administrative staff timings are from 08.15 to 16.45 hrs.

Following are the details of the persons working in General and A,B, C Shifts.

Total no. of workers employed- 1056 Total no. of staff employed- 74 Total no. of officers employed- 157 Total no. of workers present in the Shifts- 285 Average no. of workers present per day- 772

Organization (People Responsible)

To achieve the objective laid down in policy and for successful implementation and of health& safety policy, the company has following organization;

Vice-President & Factory Head

Formulate Safety, Health and Environment Policy.

G.M. (Engg. & Project)

Accountable to Vice President for monitoring the implementation of Safety, Health and Environment Policy.

Divisional Managers

Accountable for ensuring that Health and Safety arrangements are being appliedeffectively.

Departmental Heads

Accountable for follow up of work safety rules and practices.

Employees

Responsible for abiding by the Health and Safety Rules. Take reasonable care of themselves along withthatof machines,material & environment.

Manager (Safety)

Assist in promotion of Safety, Health and Environment activities in the company.

SHRIRAM RAYONS (A UNIT OF DCM SHRIRAM INDUSTRIES LTD.) EIA FOR EXPANSION OF EXISTING PLANT ADDITIONAL STUDIES


Organization Chart

Figure 7-4: Organization Chart of Factory




7.3.2 Types of Hazard during Manufacturing Process

CS2 PLANT

Fire in Molten Sulphur Fire due to leakage of CS2 (Carbon - di - sulphide) Fire in Sulphur storage Fire due to bursting of Rapture disc of furnace. Fire during refining of CS2 Leakage of H2S in CS2 refinery Generation of SO2 due to fire in Sulphur. Leakage in CS2 storage tank. Failure of CS2 storage tank. Fire while Loading of CS2 into tankers.

Viscose

Fire during addition of CS2. Explosion during addition of CS2. Leakage in Caustic /Sulphuric acid/Viscose/CS2 line. Toppling of tanker During Suphuric Acid/ DMA Unloading Failure of Sulphuric Acid/Caustic Tanks in pump house.

Spinbath

Leakage in Sulphuric Acid/Spin bath line Failure of storage tank Water logging / accumulation in Basement due to failure of sump pump

Spinning

Fire Natural Calamities Leakage in Viscose/ Spinbath Line

Textile

Fire due to spark on P.C. machines Fire due to Fluff disposition on machines

Dipping

Leakage in PNG/CNG line Fire in NDU/NCDU machines

7.3.3 Identification of Hazards

The hazards in plant have been identified as per their chemical properties and long working experience on the equipment's.

CS2 PLANT

Fire- In Charcoal, Sulphur, CS2, sludge, furnace and refinery Explosion- Due to ignition of CS2air mixture, due to high pressure in furnace and refinery Leakage- CS2 liquid, H2S, SO2gas (Toxic and Flammable)




Dipping Unit

Leakage- CNG (Flammable) Explosion- Due to ignition of CNG

Water Treatment Plant

Leakage of chlorine (During dosing of Cl2 in water through Chlorine dosing system or leakage from chlorine tonner valve or flange joints)

Viscose

Following hazards have been identified in Viscose Plant:

Fire- Due to CS2 spillage, D.M.A. or in pulp storage Explosion- During addition of CS2 in Baratte, due to rise in temperature or lowering of

vacuum Leakage- Failure of CS2 day storage tank, DMA leakage from pipe lines & tank

Textile & Dipping Unit

Fire & Explosion has been identified as main hazards in this plant. Fire due to electrical short circuit, friction in main shafts of P.C. machines, spark due to friction or electrical short circuit on machines can produce fire. Due to leakage of CNG, fire & explosion may occur in NDU area.

7.3.4 Assessment of Accident Consequences

The major accident situations in Shriram Rayons are possible when:

5. There is a failure of CS2 storage tank which catches fire. 6. Heavy leakage of chlorine from tonner of water treatment plant. 7. Explosion in CS2 furnace or Barattes. 8. Leakage of LPG,CNG due to failure of tank /line.

7.3.5 Accident History

Since the commissioning year 1965 no explosion or major fire has occurred anywhere in the plant except fire in Pulp godown in May 1998 & stray incidents in Sulphur storage, molten sulphur sludge fire is reported which is controlled by the plant operators and fire fighting staff. The stray incidents are much common during summer season when the atmospheric temperature is above 43° C. No explosion in CS2 furnace or Baratte or LPG / CNG area has occurred so far. LPG usage has been discontinued and CNG used inplace of same in plant.

7.3.6 Description on Organization Set-Up for Safety

Safety Organization

In Shriram Rayons the Safety organization is well equipped with the day to day development in safety. All the legal requirements enforced by Government of India and Rajasthan are followed and implemented. Two qualified Safety Officers are appointed. Following is the safety function organogram:




Table 7-10: Organogram for Safety S. No. Designation Address

1 Vice President & Factory Head Shriram Rayons,

At Plant Site,

Kota

2 GM (Engineering)

3 Manager Safety

4 Senior Safety Officer

Safety Policy

Shriram Rayons,Kota has a well written, documented & structured Safety & Health Policy, which is displayed at conspicuous places in complex.Safety & Health policy is circulated to all employees from time to time & is also a part of induction training. Enclosed asAnnexure 18.

Safety Training to Personnel

Safety Department imparts training to all workmen and staff members on regular basis. The motto of this training is to create awareness regarding safety & hazards in the complex & to involve all employees in developing Safe work culture. Refresher trainings are also organized for old employees.

All hazardous situations, incidents, accidents are discussed during safety trainings and solution is evolved to resolve the issues in training sessions. Fire fighting equipment are also demonstratedduring the training so that persons attending the training may know about types of fire, method of extinguishing fire and use of fire extinguisher.

These trainings are organized for Workers by IR department & for staff by Personnel department. Employees from different departments are nominated to attend the trainings.

MOCK drills are also organized in the hazardous plant to train the Workmen and staff to handle any emergencies in the plant. These are conducted by the department concerned.

Safety Activities

All the Safety Activities are initiated & controlled by the Safety Department.Following are the Major Safety Activities;

Housekeeping competition is organized in between various departments. Prizes and rolling trophy is given to the Winner in a function on National Safety Day every year. The minimum qualifying marks are 60 % this includes cleaning, Storage, Up keeping, Uniform and maintenance.

A well planned Work permit system is followed in the organization.Permit is being issued for executing routine & non routine jobs. Regular trainings are being organized for educating workers & staff regarding the work permit system procedure & its implementation.

Safety almirahs have been provided in each department. It contains the safety equipment required in emergency. A part from that PPEs are also being issued to all individual workmen & staff as per the hazard present in section by the department for regular use.

Safety Officer checks these almirahs every month and required level of the appliance is maintained by the department. A register is maintained by the user department. Safety department verifies that correct level of the appliance is maintained and condition of the safety appliances is up to the mark.

Safety trainings are organized on every Monday and Thursday for contract workmen in safety training room. Fundamentals of safety management like unsafe actions, unsafe condition, what is hazard? What is fire? Are being taught.Uses of different PPEs are demonstrated. Fire fighting training is also imparted.




Workmen, staff and officers are nominated to attend Seminars and workshops organized on safety propagation by CIFB-Rajasthan,CLI, RLI and National Safety Council, Mumbai.

Safety exhibition is organized and Audio - Video films are exhibited. Safety week and Safety Day is celebrated in which all the employees participates actively.

Safety Quiz competition & Environment Quiz competition is held every year on National Safety Day-4th March & World Environment Day-5 June .Winners are rewarded.

Safety slogan competition is organized and winning Slogans are displayed. Winners are awarded.

Safety Committee meets every three months and all safety issues,accidents, improvement and future modifications are discussed.

Safety Audit is conducted as per IS Code 14489. Once in two year by external agency and Internal Safety Audits are done annually by the maintenance and production people of the dangerous machines and equipment's. Corrective actions like repairs or replacement is done as per the Audit report.

Safety Inspections are done by the Safety Department daily and monthly. The unsafe conditions and unsafe actions are brought to the notice of the departmental in-charge and corrective actions are implemented in a stipulated time.

List of PPEs available and used

Following are the PPEs commonly used in the Factory. All the PPEs are IS/CE approved and supplied by reputed manufactures meeting the national/international standards.

Table 7-11: Details of Non–Respiratory PPEs S. No. Type of PPEs

1 Full body Harness.

2 Safety Helmets

3 Safety Shoes (Rubber, Leather, Asbestos)

4 Safety Goggles-clear lens type

5 Turner Goggles

6 Hand Gloves PVC

7 Hand Gloves Rubber

8 Hand Gloves Cotton

9 Hand Gloves Canvas

10 Hand Gloves Leather

11 Hand Gloves Kevlar

12 Gum Boots

13 Apron PVC

14 Chemical Splash Goggle

15 Boiler Suit

16 Apron Leather

17 Suit PVC

18 Hood PVC

19 Hood Asbestos

20 Face Shield

21 Welders Goggles

22 Welders Shield

23 Ear Plugs

24 Ear Muffs




S. No. Type of PPEs

25 Eye Washers

26 Safety Showers

27 Cut resistant Hand gloves

Table 7-12: Details of Respiratory PPEs S. No. Type of PPEs

1 Dusk Mask (Cartridge Type)

2 Gas Mask for DMA (Cartridge Type)

3 Gas Mask for CS2 (Cartridge Type)

4 Gas Mask for Chlorine (Cartridge Type)

5 Gas Mask for CO2 (Cartridge Type)

6 Gas Mask for H2S (Cartridge Type)

7 Gas Mask for NH3 (Cartridge Type)

8 Self-Contained Breathing apparatus

9 Full face Gas Mask

Table 7-13: Details of Fire Extinguishers at Site S. No. Type of Fire Extinguishers

1 Fire Hangers with sand and water Buckets

2 DCP Fire Extinguishers

3 CO2 Fire Extinguishers

4 Foam Fire Extinguishers

5 Soda Acid

6 Hydrant Nozzles

7 Automatic Sprinklers

7.3.7 First Aid and Antidotes

First aid kits are available at different location at site. Adequate number of first aid kits are available. Location of first aid boxes at site is given in Table 7-14. First aid kit consist of all necessary medicines, bandages and emergency tools etc.

Table 7-14: Location of First Aid Box at Site S. No. Department

1 Power House

2 Power House maintenance

3 WTP

4 Civil

5 Aux maintenance

6 Viscose

7 ACVR

8 Chemical Lab

9 Spinning

10 Preventive, Spin bath and Viscose maintenance

11 Research Lab

12 Tycord House

13 CS2

14 Instrumentation




S. No. Department

15 Electrical

16 Workshop

17 Physical Lab

18 Textile

19 Textile maintenance

20 NDU

21 Spinning maintenance

22 ASSR

23 Canteen

24 Spinbath

25 ETP

26 Godown

27 General Store

28 Electrical Control Room – PH

29 Instrument – PH

Different antidotes are also available at site. List of antidotes against chemicals are given in Table 7-15.

Table 7-15: List of Antidotes against Chemicals S. No. Name of the Chemical Antidotes

1 Acid 4% Sodium Hydro Carbonate

2 Ammonia Novasin drops for eyes

3 Ammonia Tab. Dexona, Tab. Avil

4 Chlorine Tab. Dexona, Tab. Avil

5 Chlorine Eno

6 Chlorine Black Tea

I7 Chlorine Gas Inj. Deriphyline, Inj. Phenobarbtone

8 Di Methyal Amine Methylene Blue

9 Formaldehyde Fresh air/ Milk/ Water

10 Snake Venom Anti-snake Venom Serum

11 Sulphur Wash with water

12 Sulphuric Acid Milk of Magnesia

13 Sulphuric Acid 98% Milkof Magnesia 4%, Sodium Hydrocabonate solution milk

7.3.8 Allocation and Delegation of Responsibilities for Plant Safety

The Department Heads are responsible for all the Safety activity and accident control in their respective departments.

The responsibilities have been delegated to the plant shift in-charge/ supervisors during 16:15- 07:45 hrs. Shift in-charge and senior operators are trained and responsible to handle any emergency in the absence of the department head.

7.3.9 Safety Related Activities and Emergency equipment in Plant

All the hazardous sections are equipped with Safety devices to combat the adverse situation and to save the machine and persons working.Following are the utilities employed in the plants

Table 7-16: Details of Safety System at Plant




S. No. Type of Safety System and its Location

1 Hydrant lines (All over the plant)

2 Sprinkler system (CS2), (Godown)

3 Audio - Viscous Alarms (Cl2, CS2, H2S)

4 Dyke walls (CS2 Storages)

5 Absorption system (Chlorine)

6 Mechanical ventilation system

7 Safety valves (CS2, Steam lines)

8 Rupture Disc (CS2 furnace)

9 Ammonia Torch (Chlorine)

10 Respiratory PPE's

11 Gas detectors (Cl2, CS2, H2S, SO2)

12 Sump Pit alarm (CS2 leakage)

13 Periodical Preventive Maintenance

14 Internal Safety Audit

15 Mock drill Exercises

16 Monthly checking of Departmental Safety Almirah

17 Monthly checking of fire door

18 Monthly checking of Safety Showers and Eye Washers

19 Yearly / Half yearly checking of the records of routine Workers - Medical check-up

20 Periodical Safety Training

21 Periodical Firefighting exercise and training

22 Safety Permit system

23 Explosion proof Electrical fittings

24 Risk Assessment

25 Consequences analysis

26 Hazard identification and risk analysis

27 Environment Aspect/Impact Assessment sheets

28 Periodic Environment Monitoring

29 Development of Green Belt

7.3.10 Emergency Control Plan

An onsite emergency may arise because of fire, explosion,leakage of CS2& chlorine gases, major breakdown of machines which may pose a threat to men, material, machine, building and environment. It may result into a major accident if not controlled properly & timely.

The onsite emergency plan has been prepared to control any emergency in the factory reviewing all the possible causes which may lead to a disaster. It is absolutely essential that emergency procedure should be properly planned,documented & prepared by experienced persons to act in a systematic manner to save man,material, machine, environment and surroundings, to control the situation effectively & to minimize losses & restore normal conditions.




Figure 7-5: Emergency Organization Plan

Emergency Operations

Incident Controller will lead the emergency team of his respective plant and will co-ordinate all activities under guidance/consultation with MWC. The emergency team consists of experience and trained persons to handle emergency. The emergency persons have been placed in all the shifts and general shift to encounter the emergency situations round the clock. The emergency teamunder goes mock drill exercises arranged by the incident controller to refresh the emergency operations.

Liaison Officer & Communication Officer

The Head of Security & Administration will act as Liaison & Communication Officer. He will coordinate with M.W.C. and will handle security, Police, Press and Public.

Responsibilities of Key Personnel

Main Wokrs Controller (MWC)

Overall in-charge of Emergency. To access magnitude of situation. To Maintain Continuous review of the situation with site and Incident Controller To Order the Evacuation of people, if required. To Stop Spreading of rumors. To be in touch with Govt. Officials To remain in Factory till normalcy is resorted.

Site Controller

Will direct all operations in effected area. Will maintain harmony among the persons in the plant involved in operations. Security of affected area.




Safe Shutdown of the process if required. To coordinate with Incident Controller, to preserve the evidence of the accident, to facilitate

inquiry into causes and circumstances which escalated into Emergency.

Incident Controller

Will coordinate with Emergency Teams and persons on duty, to control the situation. Decision for cutting All Electrical, Chemical and steam sources if required. Evacuation of persons from the affected area. Provision of tools &equipment required for emergency handling. Stopping the process so that no further complication arises.

Communication & Liaison Officer

To maintain communication link between MWC and Incident Controller. To arrange for messenger in case of failure of Telephones. To maintain proper Inventory of Emergency Control Centers property. To inform and call persons needed for Emergency operations. To arrange first aid teams. Will handle police, press & public. To arrange additional help of outside agencies To transport injured to hospital

Emergency Alarm

Emergency siren has been provided for sounding alarm during emergency situation. Hooter is provided at the top of the process building (Highest point) which is audible up to 8 kms. The push button to start the hooter is provided in the office of the security inspector present on duty round the clock at Gate No-2.

In case of emergency, hooter is blown with high &low pitch 3 times in one minute for 5 times, to inform/alarm persons about emergency situation in the plant.

Assembly Points

The following points are designed as Assembly points for the collection of people:

1. IRD Porch near Security Inspector shift room at Gate # 2. 2. Outside Production building.

Control Centers

There are two Control Centers from where MWC will direct all the operations during Emergency.

1. Security Inspector Shift room at Gate#2. The size of this center is 14x11 Sqft having two gates for entry and exit.

2. Control Room is outside process building. The size of this center is 15x12 Sqft having only one gate for entry and exit.

Property of Control Centers

Both the control centers are equipped with external and internal telephones. The following records are always available in these Control points;

1. Emergency onsite plans in English. 2. List of all Employees with their home address and telephone numbers. 3. Telephone Directory of important persons, places like MBS Hospital, E.S.I. & Collector etc.




Communication System

Internal Telephone has been provided in all the plants and important officers. Control Centers have internal and external telephones.Sections like Power plant, Electrical Control room and Chemical Laboratory has facility of external telephones to communicate outside the plant. Communication for Emergency is done by the hooter provided on Process building.

Communication during Failure of Telephones

Plant people and Security guards will work as messengers to carry information about emergency situations. One Vehicle is also deputed in the Factory round the clock to be used as a messenger.

Emergency Operations

As soon as the Emergency siren buzz in the Factory the operation starts. The siren buzzes 3 times at High & Low pitch in 5 minute intervals, to inform the persons.

Collection of People

As soon as the Emergency is declared in the factory, people start assembling at the assemblypoints. Actions are initiated by the senior most officers present in the Factory. Security Inspector/ Shift In-charge acts as MWC till arrival of the MWC.

Operations by MWC

As soon as the MWC arrives he is briefed by the officer present who initiated the preliminary actions and the latest situation about the Emergency

The Site Controller, Communication Officer, Liaison Officer, First Officer Co-ordinate with MWC and remain in the Control Centre till action is finalized on the information gathered from site of Emergency.

Rescue and First Aid

Rescue operations are done by emergency teams. Security staff, Fire fighters. The injured are shifted to the OHC situated at Gate#2.

Onetrained male nurse is deputed round the clock in OHC. MBBS Doctor is available during general shift hours. Doctor is also called in emergency. The injured are sent to MBS,ESI & Private hospitals as per the advice of the Doctor / Male nurse present.An Ambulance Van is also available at OHC round the clock.Equipment available in OHC at site is given in Table 7-17. First aid boxes are available at different location at site which are given in Table 7-14

Table 7-17: Equipment available at OHC S. No. Equipment at OHC

1 ECG Machine

2 Glucometer

3 Oxygen Cylinder -2

4 Suction Apparatus

5 BP Instrument

6 Weighing Machine

7 Vision Test equipment

8 Knee Hammer

9 Ambulance




S. No. Equipment at OHC

10 Stretcher - 8

11 First Aid Boxes - 33

12 Urine test strips

13 Colour Blindness Test

14 Measurement tapes

15 Examination Coach - 2

16 Infrared Lamp

Photographs 7-2: Photographs of OHC




Liaisoning

The Liaison officer is responsible for contacting doctors, public and police and to send injured to the hospitals as per the situations arises.

Roll Call

Persons deputed in emergency operations and persons present inside plant are counted at the end when emergency situation is under control.Search is made for the person not present in the Roll Call, concerned HOD of missing employee & security department is responsible for locating the missing person.Security Department/Shift in-charge security is responsible for head counts;he can take assistance from IRD/HRD for head count process.

The MWC visit the complete site along with his team and review the situation. Evaluation of machinery, building and material loss is done. MWC declares all clear after the situation is being accessed by him & found to be under control.All Clear siren is to be blown by shift in-charge security from gate no 2.

All necessary instructions are given to the Incident Controller by MWC, not to alter anything on the site so that investigation can be done and actual cause of accident can be found out.

When normalcy is restored in the plant the MWC can leave the Factory.

Persons Responsible for Handling Emergency Situation after Normal Working Hours

Factory runs in "8"hr shifts namely A-shift 07:00-15:00 hr;B-shift 15:00-23:00 hr;C-shift 23:00-07:00 hr; The "G" shift timings are 07:45-16:15 hr for Works and 08:15-16:45 hr for Administration/Commercial. After 16:45 hr the following persons are responsible for handling emergency till the MWC reaches in the Emergency Control Centre.

Control Room Officer (CRO)

One officer is deputed every day from 22:00-06:30 hrs to look after the factory activities.

He is solely responsible to coordinate all activity between 22:00-06:30 hr in the factory. He will act as MWC to handle any emergency till the MWC arrives.

Security Inspector

The Security Inspector is present in "8" hrs shift. From 16:45 - 22:00 hrs till the CRO reports on duty,Security Inspector will be responsible tocoordinate the actions in case of emergency. His responsibilities are as following:

Pass information to MWC, Site Controller and Incident Controller. Arrangement of necessary help where emergency arises.




Cordon off the affected area. Traffic Control. Calling emergency and firefighting team. Fire fighting till the fire officer arrives & takes charge. Controlling the situation with concerned shift in-charge till MWC,Site controller & incident

controller arrives.

7.3.11 Internal Hazards

Fire in Charcoal Storage, Sulphur Storage CS2 Plant, CS2 Area, DMA Storage, Baratte Room, Diesel Storage, Nylon Dipping Unit, LPG Storage Area, Captive Power Plant, ASSR Section, Canteen and Transformers & Electrical Panels

Explosion in CS2 Furnace Area and Baratte Room Failure of CS2 Storage Tanks (CS2 Plant), CS2 Day Storage Tanks (Viscose Plant), Sulphuric

Acid Storage Tank, Caustic Storage Tank Chlorine Gas Leakage from Tonner (Water Treatment Plant) Leakage in Viscose Line and Spinbath Line

7.3.12 External Hazards

Earthquake

In case of earthquake move out of the plant & rush to nearest open area. Security to blow siren as per the Emergency procedure. Liaison Officer & Communication Officer (Head Security & Administration) keeps MWC

updated. After the tremor ceases Main works controller/Site Controllers & Incident Controllers take

round of the plant to access the damage, if any. In case of any accident, make arrangements to evacuate the victims from the affected area. Nursing staff to provide first aid to victim, & if needed victim to be shifted to nearest medical

facility. Head count to be done by incident controller in consultation with security. HOD/Incident controller to arrange the resources to clear the rubbish if any. After the calamity the Engineering Head to take round of the plant with factory Head for

accessing the damage or critically affected area for necessary precautionary measures. All employees to ensure use of appropriate PPEs while entering affected area.

Social Unrest

In case of social unrest in the city or adjoining area.Personnel & IR department and Liaison Officer & Communication Officer to update Main Works controller about the persons belonging to affected area & seek his advice on appropriate course of action.

Liaison Officer & communication officer will co-ordinate with city administration for arranging necessary help to ensure protection of plant property from any sabotage.

Incident Controllers In coordination with liaison & communication officer will keep strict watch on Hazardous Chemical storages in their respective areas.

Major Fire in the Vicinity of Plant

Liaison & communication officer will coordinate with authorities of nearby industry to assess the severity of incident & update MWC.

Fire tender along with fire crew to be kept ready to handle the emergency situation.




Incident controllers should ensure running of water sprinkler provided on hazardous chemical storage tanks in their area.

Liaison& communication officer to ensure medical staff/first aid team is ready to meet emergency.

If required, the emergency siren to be blown.

7.3.13 Offsite Emergency Response Plan

An emergency situation which poses threat to property, life or environment outside the premises of Shriram Rayons is termed as an offsite emergency situation.

Probable Offsite emergency scenarios which may occur due to our operations are:

Road accident / leakage of Carbon di sulphide tanker during transit. Fire/Explosion of Carbon di sulphide tanker during transit. Road accident/Fire in finished good container during transit. Major leakage of CS2 gas, followed by fire & explosion. Leakage of chlorine gas from chlorine tonner. Fire in Husk storage Yard at Khazuri.

Action Plan for Offsite Emergency Handling:

In case of any offsite emergency the first responder/ vehicle driver in case of CS2& finished goods container has to inform Sr. Manager-Security & Admin on his contact number. Information regarding contact number is given in documents given to the driver oftanker/container.

Sr. Manager Security & Admin intern inform Vice President (Unit Head) about the offsite emergency & also contact the local police station nearest to the site of incident.He also directs the driver to ask help from local administration of the incidental area.

Sr. Manager-Security & Admin directs the movement of rescue team to the incident site in consultation with unit head as per the situation demand.

Sr. Manager Security & Admin Liaison up with district administration of Kota forexecution/implementation of District Offsite Emergency Plan under leadership of DistrictMagistrate of Kota. Sr. Manager-Security & Admin is responsible for dove tailing Offsite emergency plan of Shriram Rayons with Kota district offsite emergency plan. Shriram Rayons may also lend a helping hand to district administration for coping Offsite Emergency by providing infrastructure & technical support at the time of exigencies.

7.4 Public Consultation

7.4.1 Focus Group Discussion

Group discussion with the public is an integral component of Social and Need assessment and project design. Without community consultation, a project will not reflect issues or solutions identified by local residents, and a lack of it can result in missed data, in addition to missed opportunities to share experiences and identify solutions to difficult concerns/issues. The Social Impact assessment of the proposed plant is required to include community consultation. At this early stage in the process, consultation has been focused on to know the community perception about the socio-economic conditions of the project area. The public consultation is carried out at following locations during initial surveys. The Details are given in Table 7-18.




Table 7-18: Focus Group Discussion at Village Level Place of Meeting with Date

S. No. Village Date

1 Khera Rasoollpura 17 September 2014

2 Mawasa 19 September 2014

Name of Participants

Kadam Socio-Economic Team:- Dr. Dushyant Mishra, Mr. Ashish K. Pandey

S. No. Village Participants

1 Khera Rasoolpura

Ms. Buli Bai Malo (+91 941 466 1546) - Sarpanch

Mr. Rajendra Arya (+91 941 466 1692) – Dpy. Sarpanch

Mr. Ram Karan ji (+91 809 407 2124) – Secretary

Mr. Om Prakas Malaw (+91 946 873 7224)

Name of villages under Gram Panchayat: 1. Arampura, 2. Jal kheda, 3. Chaipura, 4. Bojpura, 5. Khera, 6. Rasoolpura

2 Mawasa

Ms. Guddi Gurjar (+917568683806) – Sarpanch Mr. Ramendra Singh

Mr. Shankar Lal Gurjar, Dy. Sarpanch, Boriyakhedi

Name of villages under Gram Panchayat: Total 9 villages comes under this Panchayat

1. Mawasa, 2. Dhandi, 3. Boriyakhedi, 4. Jampura, 5. Prahladpura, 6. Ganeshpura, 7. Chhipanhedi, 8. Shambhupura, 9. Ruparel

Issues Discussed during group discussion are as following;

Health and Sanitation facilities Gender Empowerment through school infrastructure Condition of Girls Education Condition of Basic Infrastructure facilities Awareness generation from chemical disaster Condition of quality of life Employment condition Condition of drinking water facilities

Documents

20150620 EIA Final