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Report No: GCCIPL/V/GODREJ/OEP/2010-11/MAY/RMS-043/R00
ON SITE EMERGENCY PLAN
REPORT
PREPARED FOR
M/S. GODREJ & BOYCE MFG. CO. LTD.
DAHEJ, BHARUCH
CONDUCTED & PREPARED BY
GREEN CIRCLE CONSULTANTS (I) PVT LTD. Environmental, Health, Hygiene, Safety, Risk, & Quality
Consulting Engineers & Trainers
(An ISO 9001: 2008 Certified Company)
ALSO AT NEW DELHI MUMBAI PUNE BANGALORE HYDERABAD
OVERSEAS: AUSTRALIA OMAN QATAR DUBAI NIGERIA
M/s. Godrej & Boyce Ltd. On Site Emergency Plan for Proposed Engineering unit along with Jetty in
CRZ area at SEZ - Dahej Report No: GCCIPL/V/GODREJ/OEP/2010-11/MAY/RMS-043/R00
Green Circle Consultants (I) Pvt. Ltd.
QUALITY CONTROL SHEET
Rev. Date Reason History Prepared
By
Reviewed
By
Approved
By
00 24/05/2010 Draft Report of On Site
Emergency Plan AT DD NP
AT : Apexa Thaker DD : Dipali Desai NP : Narendra Parmar Prepared by Apexa Thaker, Executive-EHS
Signature
Reviewed by Dipali Desai, Asst. Manager
Signature
Approved by Narendra Parmar, Asst. General Manager
Signature
Released by Nachiket Joshi, Group Manager-A & F
Signature
M/s. Godrej & Boyce Ltd. On Site Emergency Plan for Proposed Engineering unit along with Jetty in
CRZ area at SEZ - Dahej Report No: GCCIPL/V/GODREJ/OEP/2010-11/MAY/RMS-043/R00
Green Circle Consultants (I) Pvt. Ltd.
ACKNOWLEDGEMENT
WE EXPRESS OUR SINCERE THANKS TO MANAGEMENT & EMPLOYEES OF
GODREJ & BOYCE LTD., DAHEJ, BHARUCH, FOR THEIR CO-OPERATION &
UNSTINTED HELP WITHOUT WHICH THE ’ON SITE EMERGENCY PLAN’ COULD
NOT HAVE BEEN POSSIBLE. THE COURTESY EXTENDED TO OUR TEAM IS
HIGHLY APPRECIATED.
For: GREEN CIRCLE CONSULTANTS (I) PVT.LTD.
AUTHORISED SIGNATORY
M/s. Godrej & Boyce Ltd. On Site Emergency Plan for Proposed Engineering unit along with Jetty in
CRZ area at SEZ - Dahej Report No: GCCIPL/V/GODREJ/OEP/2010-11/MAY/RMS-043/R00
Green Circle Consultants (I) Pvt. Ltd.
INDEX
CHAPTER CONTENTS PAGE NO.
Introduction to On Site Emergency Plan 1.1 General
1.2 Statutory requirement for Onsite plan 1.
1.3 Scope of the plan
Overview of the Unit
2.1 Introduction
2.2 Location
2.3 Details of factory
2.
2.4 Organization structure
Unit Hazard & Control
3.1 Evaluation of Hazards
3.2 Storage Hazards
3.3 Hazards
3.4 Process description
3.5 Safety measures for LPG storage
3.6 Safety measures for Compressed Gas
Cylinders
3.7 Utility
3.8 Other safety measures
3.9 Safety measures for solvents storage and
handling
3.
3.10 Safety and Mitigating measures
Environment Impact Assessment
4.1 Introduction
4.2 Layout of the Unit
4.3 Effluent Treatment Plant
4.
4.4 Noise Level
M/s. Godrej & Boyce Ltd. On Site Emergency Plan for Proposed Engineering unit along with Jetty in
CRZ area at SEZ - Dahej Report No: GCCIPL/V/GODREJ/OEP/2010-11/MAY/RMS-043/R00
Green Circle Consultants (I) Pvt. Ltd.
4.5 Solid Waste
4.6 Consents from GPCB
Accident History
5.1 Introduction
5.2 Accident Reporting System
5.3 First Aid Box
5.
5.4 Medical Examination
Organization Plan
6.1 Introduction
6.2 Identification of Hazards and Control
Measures
6.3 Planning for Emergency
6.4 Command & Control
6.5 Incident Controller
6.6 Site Main Controller
6.7 Key Personnel
6.8 Essential Workers
6.9 Safe Assembly Point
6.
6.10 Check Schedule
Emergency Procedure
7.1 Actions during Emergency
7.2 Sequential Actions during Emergency
7.3 Emergency Actions (General)
7.4 Emergency Communication
7.5 Action Plan for Emergency In-Charge
(IC/SMC)
7.
7.6 Action Plan for In-Charge of Emergency
Control Center i.e. Communication
Officer
M/s. Godrej & Boyce Ltd. On Site Emergency Plan for Proposed Engineering unit along with Jetty in
CRZ area at SEZ - Dahej Report No: GCCIPL/V/GODREJ/OEP/2010-11/MAY/RMS-043/R00
Green Circle Consultants (I) Pvt. Ltd.
7.7 Action plan for Key Personnel and
Essential Workers
7.8 Action plan for Security Guards/ Officer
7.9 Action Plan for Workers/Officers
/Contractor
7.10 Discipline
7.11 Shut down Procedure
7.12 Post Emergency
7.13 Corrective Actions
Annexure Section
Appendix Section
M/s. Godrej & Boyce Ltd. On Site Emergency Plan for Proposed Engineering unit along with Jetty in
CRZ area at SEZ - Dahej Report No: GCCIPL/V/GODREJ/OEP/2010-11/MAY/RMS-043/R00
Green Circle Consultants (I) Pvt. Ltd. 1
CHAPTER – 1
INTRODUCTION OF ON-SITE EMERGENCY PLAN
M/s. Godrej & Boyce Ltd. On Site Emergency Plan for Proposed Engineering unit along with Jetty in
CRZ area at SEZ - Dahej Report No: GCCIPL/V/GODREJ/OEP/2010-11/MAY/RMS-043/R00
Green Circle Consultants (I) Pvt. Ltd. 2
ON SITE EMERGENCY RESPONSE & MANAGEMENT 1.1 General
It is impossible to forecast the time and nature of emergency, which might
strike the unit. In spite of the fact that every industry is expected to take steps
to assess, minimize and wherever feasible eliminate risks, accidents may
occur, as risk can only be minimized, it can never be totally eliminated.
Industrial units are vulnerable to various kinds of natural and man-made
emergencies. Examples of Natural disasters are flood, Cyclone, earthquake,
lightening etc. and man made disasters like major fire, explosion, sudden
heavy leakage of toxic / flammable gases, civil work plant failure, human
errors, vehicle crash, sabotage etc.
The emergency is an undesirable occurrence of events of such magnitude
and nature that adversely affect production, cause loss of human lives and
property as well as damage to the environment.
Controlling the emergency will require prompt action by the operating staff,
the staff of various agencies, emergency teams and outsiders when called
for. Minimizing the effect on people may be achieved by prompt
communication, rescue, evacuation etc., if the situation so warrants.
However, an effective emergency plan helps to minimize the losses in terms
of human lives, plant assets and environmental damage and to resume the
working condition as soon as possible. In all these steps SPEED IS THE ESSENCE.
As a part of emergency preparedness, keeping in the view the potential
hazards prevailing in the factory and effect of such hazards, the On-Site
Emergency Action Plan has been prepared.
M/s. Godrej & Boyce Ltd. On Site Emergency Plan for Proposed Engineering unit along with Jetty in
CRZ area at SEZ - Dahej Report No: GCCIPL/V/GODREJ/OEP/2010-11/MAY/RMS-043/R00
Green Circle Consultants (I) Pvt. Ltd. 3
1.2 Statutory Requirement for Preparation of On-site Emergency Plan
The unit, which is covered under chemical hazardous factory, has to
prepare the On-Site Emergency Plan with indicating what preventive
measure has been taken against hazards and how to fight emergency. This
plan has to be submitted to the specified authorities. It is also provided that
the periodical rehearsals / exercises are also required to be conducted.
The provisions for preparing the on-site emergency plan are explained on
next page:
1.2.1 The Factories Act, 1948 (1987) & Gujarat Factory Rules 1963 (1995)
Section 7 A (2) & 41 (B) of The Factories Act 1948 (1987) and Rules 68-J (12)
of the Gujarat Factories Rules 1963 (1995) providing that the every
occupier, who has control of an industrial activity pertaining to hazardous
chemical shall furnish the On-Site Emergency Plan detailing how major
accidents shall be dealt with along with explaining specific responsibilities
and actions by various persons.
1.2.2 The Environment (Protection) Act- 1986 (2001)
Rule 13 (1) under the Manufacture, Storage and Import of Hazardous
Chemicals Rule 1989 (Amended 2000), rules framed under The
Environment (Protection) Act -1986 (2001), indicates that the occupier
shall prepare and keep up-to-date as On-Site Emergency Plan containing
details specified in schedule II and detailing responsibilities and actions by
different person and agencies.
M/s. Godrej & Boyce Ltd. On Site Emergency Plan for Proposed Engineering unit along with Jetty in
CRZ area at SEZ - Dahej Report No: GCCIPL/V/GODREJ/OEP/2010-11/MAY/RMS-043/R00
Green Circle Consultants (I) Pvt. Ltd. 4
1.2.3 Chemical Accidents (Emergency Planning, Preparedness and
Response) Rule 1996 (2000)
Under this rules, framed under The Environment (Protection) Act 1986, the
state government has constituted local crisis group & District Crisis Group
to deal with major chemical accidents and to provide expert guidance
for handling chemical accidents. Further provision is made that the Major
Accident Hazard units have to prepare the on-site emergency plan &
submit the plan to the crisis groups. The local emergency plan will dovetail
with the District off-site emergency plan.
1.2.4 Off-Site Emergency Plan
The emergency planning for on-site and off-site are different but they
should be dovetailed with each other. On-site emergency planning is the
responsibility of the site management, while offsite planning is for the
whole district having responsibility casts to district authorities like District
Magistrate & Collector, Factory Inspector, Police Department, Fire
Brigade, Health & Medical Services, Pollution Control Board, Explosive
Department etc.
1.3 Scope of the Plan
The emergency procedure as outlined herein is designed with the primary
aim of protecting, to the greatest extent possible, all employees, persons, in
the vicinity and company property against fire, explosion, spills, or other
major accident of disastrous proportion, which might arise as a result of our
own operations, processes, storage, adjacent operations, or any other
circumstances.
M/s. Godrej & Boyce Ltd. On Site Emergency Plan for Proposed Engineering unit along with Jetty in
CRZ area at SEZ - Dahej Report No: GCCIPL/V/GODREJ/OEP/2010-11/MAY/RMS-043/R00
Green Circle Consultants (I) Pvt. Ltd. 5
This plan is prepared basically to cope with any emergency, which could
occur during storage or process, at any time of the day or night or
weekends.
The success of this plan in accomplishing its purpose depends largely upon
each individual carrying out his designated duties effectively and promptly.
This plan is in three sections. The first section provides basic requirements,
which explains essential elements of the plan.
The second section is Annexure Section, which is designed to give specific
information needed during emergency.
The third section is Appendix Sections, which gives additional useful
information and details for preparation & handling of emergency.
An emergency cannot be always prevented, but it can be controlled within
limits and its effects can be minimized by using the best available resources,
at the time.
The emergency planning is a management function and it should not be
considered in isolation. The Management should evaluate the activities,
operations and processes carried out within the works before starting to
plan an emergency operation. A check must be kept to ensure that all
necessary steps are taken which are included in emergency planning.
Considering the number of employees, material and process, availability of
resources, location of site, size and complexity of the works, we have
prepared this plan. This plan may be updated in case any new material is
added, revision of process or change of method etc.
M/s. Godrej & Boyce Ltd. On Site Emergency Plan for Proposed Engineering unit along with Jetty in
CRZ area at SEZ - Dahej Report No: GCCIPL/V/GODREJ/OEP/2010-11/MAY/RMS-043/R00
Green Circle Consultants (I) Pvt. Ltd. 6
CHAPTER – 2
OVERVIEW OF THE UNIT
M/s. Godrej & Boyce Ltd. On Site Emergency Plan for Proposed Engineering unit along with Jetty in
CRZ area at SEZ - Dahej Report No: GCCIPL/V/GODREJ/OEP/2010-11/MAY/RMS-043/R00
Green Circle Consultants (I) Pvt. Ltd. 7
2.1 Introduction
Godrej & Boyce Mfg. Co. Ltd. is a private limited company. Godrej & Boyce
Mfg. Co. Ltd., is today one of the largest Engineering and Consumer products
company in the country having varied interests from engineering to personal
care products. It has its manufacturing two units located at Mumbai
(Maharashtra).
Company is intending to put their new engineering unit for “Fabrication of
Heat Exchanger, Pressure Vessels & Columns” along with Jetty in CRZ area at
SEZ – Dahej, Gujarat to cater the global market demand.
2.2 Location:
The Project is planned in Plot no. Z – 90, SEZ - Dahej, Village - Luvara, Taluka -
Vagra, District – Bharuch, Gujarat State, India. Total Plot area for Project shall
be 235030 m2.The project site is located on 210 39’ 36.02” North latitude and
720 33’ 22.92” East longitude. The average mean sea level is 4 mtr.
In the immediate vicinity the site is bounded on four sides by:
East: IPCL (RIL) Jetty
West: Gulf of Khambhat
North: Petronet LNG Terminal
South: Narmada River
LAYOUT OF FACTORY: The topography of the proposed plot is not flat in shape. There is no dense
natural vegetation around the site. Construction of new Industrial engineering
unit for “Fabrication of Heat Exchanger, Pressure Vessels & Columns” along with
Jetty is proposed. The existing land use pattern is Industrial Zone and out of
M/s. Godrej & Boyce Ltd. On Site Emergency Plan for Proposed Engineering unit along with Jetty in
CRZ area at SEZ - Dahej Report No: GCCIPL/V/GODREJ/OEP/2010-11/MAY/RMS-043/R00
Green Circle Consultants (I) Pvt. Ltd. 8
235030 m2 areas only 41028.90 m2 shall be used for the proposed unit of
fabrication of process related equipments. The area allotted for jetty will be
3960m2. Green belt area shall be 49207 m2. The remaining plot shall be
developed in future.
The Project Land Use Plan describes two categories of land uses: Unit for
fabrication of Heat Exchanger, Pressure Vessel & Columns is proposed in the
processing area. The unused land will be used for captive consumption in future
for further plant expansion. The space will be spare for future electrical substation
and other infrastructure facilities like internal roads, lights, STP / ETP. Design for the
same will be created at the time of actual planning for expansion of the units.
The Factory is mainly divided into following sections or Blocks as:
PROCESSING ZONE
Administrative building
Open fabrication yard (Phase I)
Common open Plot (Phase II)
Future expansion (Phase III)
LPG bullet area
Parking area
Green Belt area
UTILITY
The Utility block encloses Fabrication Air Compressor, Heat exchanger, Thermic
Fluid System, DG set etc.
ETP
Effluent Treatment Plant design for 300 m3 / day for M/s. Godrej & Boyce Mfg.
Co. Ltd., Dahej.
M/s. Godrej & Boyce Ltd. On Site Emergency Plan for Proposed Engineering unit along with Jetty in
CRZ area at SEZ - Dahej Report No: GCCIPL/V/GODREJ/OEP/2010-11/MAY/RMS-043/R00
Green Circle Consultants (I) Pvt. Ltd. 9
The ETP consists of Receiving Sump, Aeration Tank, Secondary clarifier, Flash
mixer, flocculator cum clarifier, Treated Effluent Sump, Pressure Filter, Activate
carbon Filter, Filter Press, Equalization Tank & all rest primary and secondary
treatment units.
NON PROCESSING ZONE
Corporate office
Pantry / Canteen
Security Cabin
Car Parking (11502.86 m2)
Truck Parking
Over Head Water Tank
Water Harvesting System
Temple
Labor Welfare Office
The layout of unit is given in Annexure-3.
2.3 Details of the Factory:
Sr.
No. Descriptions Details
1 Name & Address of Unit
A Unit for fabrication of heat exchanger,
pressure vessels & columns at Godrej & Boyce
Mfg. Co. Ltd Taluka - Vagra, District-Bharuch,
State-Gujarat
2 Regd. Office Address
Godrej & Boyce Mfg. Co. Ltd.
Pirojshanagar, Vikhroli,
Mumbai – 400 021.
Mobile: 98205 22010
M/s. Godrej & Boyce Ltd. On Site Emergency Plan for Proposed Engineering unit along with Jetty in
CRZ area at SEZ - Dahej Report No: GCCIPL/V/GODREJ/OEP/2010-11/MAY/RMS-043/R00
Green Circle Consultants (I) Pvt. Ltd. 10
3 Telephone No. (022) 67962051
4 Fax No. (022) 67961501
5 TELEX -
6 E-mail [email protected]
7 Name & Address of Occupier
of Factory
Mr. Anil G Verma
Executive Director cum - Head ( P&A )
Godrej & Boyce Company Ltd.
Plant-12,Corporate Personnel Department
Pirojshanagar, Vikhroli,
Mumbai - 400 079, MS, India
8 General Manager of Factory Mr. Nitin S Palan
9 Finished Products Fabrication of various process equipments like
heat exchangers, pressure vessels & columns.
10 Process involved
1. Inspection & Marking
2. Machine cutting & gas cutting
3. Cold rolling
4. Welding
5. Fabrication
11
Hazardous Chemicals
Hydrogen
Acetylene
Liquefied Petroleum Gas
a) As per listed under schedule-1 of Rule 68-
J of GFR 1963 (1995).
b) The quantities of the identified hazardous
chemicals under MSIHC Schedule-I are
much below the applicable / permitted
threshold quantities as per Schedule-II.
12
Factory License from Factory
inspection Department, Gujarat
State
Under Process
13 License from Department of
Explosives -
M/s. Godrej & Boyce Ltd. On Site Emergency Plan for Proposed Engineering unit along with Jetty in
CRZ area at SEZ - Dahej Report No: GCCIPL/V/GODREJ/OEP/2010-11/MAY/RMS-043/R00
Green Circle Consultants (I) Pvt. Ltd. 11
2.3 Details of Units (Continue…)
Sr.
No. Descriptions Details
14 GPCB Consent
NOC application is done. CC&A application will
be done well in advance before
commencement of operation.
15 Facility/System
(1) All electrical equipments, wiring &
fitting shall be flameproof type.
(2) Provision of D.G. Set to meet
emergency.
(3) Provision of water storage.
(4) Water sprinkler system shall be installed
in the plant.
(5) Provision of portable fire extinguishers &
fire buckets.
(6) Well ventilated storage area.
(7) Provision of Earthing
(8) Smoking is prohibited
(9) Trained & Experienced persons.
(10) Arrangement of Siren/Bell/Messages
(11) Auto control, Control Room, Internal
Phone.
(12) Communicator system, Mobile phone,
Fax, E-mails, etc.
(13) Displayment of Notices
(14) Color Code system for Pipe Lines.
(15) First Aid Trained Person.
M/s. Godrej & Boyce Ltd. On Site Emergency Plan for Proposed Engineering unit along with Jetty in
CRZ area at SEZ - Dahej Report No: GCCIPL/V/GODREJ/OEP/2010-11/MAY/RMS-043/R00
Green Circle Consultants (I) Pvt. Ltd. 12
2.4 Organization Structure: The detail of Organization Structure is given in the Appendix-B.
CHAPTER – 3
UNIT HAZARD & CONTROL
M/s. Godrej & Boyce Ltd. On Site Emergency Plan for Proposed Engineering unit along with Jetty in
CRZ area at SEZ - Dahej Report No: GCCIPL/V/GODREJ/OEP/2010-11/MAY/RMS-043/R00
Green Circle Consultants (I) Pvt. Ltd. 13
3.1 Evaluation of Hazards:
Hazard is a physical situation which may cause human injury, damage to
property or the environment or combination of these criteria. Hazard
identification provides vital information to risk management.
The unit is engaged in fabrication of heat exchanger, pressure vessels &
columns. Main components of the unit are as follows:-
1) Storage
2) Process
3) Utility
3.2 Storage Hazards The following substances are stored at various places of the premises:
TABLE 1 STORAGE FACILITY FOR RAW MATERIALS
Sr.No Raw Material
No. of container &
size (MT)
Pres--sure
Kg/cm2
Temp (˚C )
Total Quantity
(MT)
Type of Hazard
Consumption MT/
annum No. Size
1 Carbon Steel
N.A N.A N.A N.A 810 MT Non-combustible
9720
2 Stainless Steel
N.A N.A N.A N.A 40 MT Fumes / gases
produced from
welding or burning
operations
480
3 Mild Steel – 410
N.A N.A N.A N.A 365 MT Fumes / gases
produced from
welding or burning
operations
4380
4 Other N.A N.A N.A N.A 135 MT May be 1620
M/s. Godrej & Boyce Ltd. On Site Emergency Plan for Proposed Engineering unit along with Jetty in
CRZ area at SEZ - Dahej Report No: GCCIPL/V/GODREJ/OEP/2010-11/MAY/RMS-043/R00
Green Circle Consultants (I) Pvt. Ltd. 14
metals Flammable 5 Oxygen 145 7 m3 150
kg/cm2 Ambient 1015 m3 Non
flammable 181200
6 Argon 40 7 m3 150 kg/cm2
Ambient 280 m3 Non Flammable
68760
7 Hydrogen 3 5.5m3 150 kg/cm2
Ambient 15.6 m3 Flammable gas &
Asphyxiant
600
8 Nitrogen 50 7 m3 150 kg/cm2
Ambient 350 m3 Non Flammable
4380
9 Acetylene 50 7 m3 16-18 kg/cm2
Ambient 350 m3 Explosion 24876
10 Carbon dioxide
30 30 Kg 150 kg/cm2
Ambient 900 Kg Non Flammable
38880
11 Thinner 30 20 L N.A Ambient 600 L Flammable 21600 12 Hydro
Fluoric Acid
10 35 Kg N.A Ambient 350 Kg Corrosive in nature
600
13 Nitric Acid 17 35 Kg N.A Ambient 595 Kg Health hazard
5160
14 M3 Degreaser
100 5 Kg N.A Ambient 500 Kg Slightly pungent
240
15 Primer 10 20 Lit N.A Ambient 200 L Fire & health hazard
2160
16 Other paints
100 20 Kg N.A Ambient 2000 Kg
Health hazard
37740
17 Hydraulic oil
10 210 L N.A Ambient 2100 L NA 24300
18 Grease 1 5 Kg N.A Ambient 5 Kg NA 18 19 Turpentine 5 20 L N.A Ambient 100 L Flammable 3240
Refer Annexure – 4 Storage Hazards
Refer Annexure – 5 Material Safety Data Sheet
M/s. Godrej & Boyce Ltd. On Site Emergency Plan for Proposed Engineering unit along with Jetty in
CRZ area at SEZ - Dahej Report No: GCCIPL/V/GODREJ/OEP/2010-11/MAY/RMS-043/R00
Green Circle Consultants (I) Pvt. Ltd. 15
STORAGE FACILITY FOR HAZARDOUS CHEMICALS
Sr. No.
Name Of Chemical Type of Storage
Storage Quantity
Type of Hazard
Hydrogen Cylinder 110 CMT Flammable gas & Asphyxiant
Acetylene Cylinder 110 CMT Explosion
1 Flammable Gases
LPG Bullet/Cylinder 6 Ton Flammable
HSD Tank 1250 ltrs Flammable liquid
Nitric Acid Carboys(35 lit) 300 kg Health hazard Primer Tin Container 300 ltrs Fire & health
hazard Other paints
Tin Container 300 ltrs Health hazard
Thinner Tin Container 920 kg Flammable
2 Flammable Liquids
Turpentine Tin Container 300 ltrs Flammable
Note: The quantities of the identified hazardous chemicals under MSIHC
Schedule-I are much below the applicable / permitted threshold quantities as
per Schedule-II.
Details of Fuel Consumption
SR. NO. NAME OF FUEL QUANTITY / MONTH
1 LPG 60700 KG 2 CNG 28000 SCM 3 HSD 7500 LTR
M/s. Godrej & Boyce Ltd. On Site Emergency Plan for Proposed Engineering unit along with Jetty in
CRZ area at SEZ - Dahej Report No: GCCIPL/V/GODREJ/OEP/2010-11/MAY/RMS-043/R00
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3.2. Storage All storage tanks, bullets, cylinders are above ground, located safe distance
away from the plant and the storage tanks will be under strict safety conditions.
The storage facilities includes the storage of flammable gases like LPG,
Acetylene, Hydrogen and flammable liquids like HSD, Nitric acid and Turpentine
tin containers.
3.3 Hazards As far as storage hazards concerned, the following probable emergency
situations may arise, while handling, transporting and using the types of
materials.
(1) FIRE: 1. Generation of Static Electricity
2. Electrical Short Circuit
3. Transformer area
4. Diesel Oil
5. Solvents Storage
6. Tank farm area
7. Electrical Sub Station
8. Fabrication Yard
9. Compressed gas Storage Unit.
(2) EXPLOSION:
1. Bullet of LPG,
2. Cylinder of Hydrogen & Acetylene
(3) LEAKAGE & SPILLAGE OF:-
1. Nitric acid
M/s. Godrej & Boyce Ltd. On Site Emergency Plan for Proposed Engineering unit along with Jetty in
CRZ area at SEZ - Dahej Report No: GCCIPL/V/GODREJ/OEP/2010-11/MAY/RMS-043/R00
Green Circle Consultants (I) Pvt. Ltd. 17
2. Hydrogen
3. Acetylene
4. Primer
5. HSD
6. Thinner
7. Other paints (Solvents)
8. Turpentine
3.4 PROCESS DESCRIPTION The company is engaged in fabrication of heat exchanger, pressure vessels &
columns at Godrej & Boyce Mfg. Co. Ltd Taluka - Vagra, District-Bharuch, State-
Gujarat.
Brief Description of Manufacturing Process of Process Equipment Division The manufacturing process of Process Equipment Division comprises of following sub-processes:
1. The raw material is received in the form of heavy thickness plates and stored for the manufacturing process.
2. The material received from Raw materials stores is first inspected and
marking is done on the raw material as per drawing of item to be fabricated. Also the cutting is done in accordance top the marking.
3. The plates cut to size are cold rolled to the required diameter of shell.
After the plate is rolled its two ends are joined to form a shell of a diameter raging from 600 mm to 6 meters by welding. Longitudinal shell welding and circumferential seam welding is done.
4. The machining work for various fabricated components required for the
fabrication of Heat Exchangers, Pressure Vessels, Column jobs etc is carried out.
5. Fabricated Nozzles required for the fabrication of Reactors, Vessels, Heat
Exchangers & Columns are prepared.
M/s. Godrej & Boyce Ltd. On Site Emergency Plan for Proposed Engineering unit along with Jetty in
CRZ area at SEZ - Dahej Report No: GCCIPL/V/GODREJ/OEP/2010-11/MAY/RMS-043/R00
Green Circle Consultants (I) Pvt. Ltd. 18
6. All the components and subassemblies are assembled to make the final fabricated product.
7. The final fabricated product is tested, inspected, treated, cleaned and
painted as per the requirements specified in the drawings.
8. The final fabricated product is dispatched. 3.5 Safety Measures for LPG storage
LPG, being highly volatile and inflammable liquid, poses the greatest
potential for fire and explosion. The following Safety measures shall be
installed for the storage facilities.
1. Fire Hydrant System
2. Automatic fire detection system
3. Fire extinguishers & trained personnel
4. Electrical lockouts, gas tests and hot work permit
5. Ventilation and air pollution control
6. Gas monitoring system
7. Leak & fault detection sensors
8. “No Smoking Signs”
9. Bunding
10. Minimum separation distance as per the applicable rules
11. Emergency control valve (in plant storage area)
12. Shut-up valve
13. Safety valves – 2 no.
14. Level switch (High and low)
15. Pressure Measuring Switch
16. Remote control fittings & valves (fire-safe & fail-safe)
17. Electrical installations flameproof
18. Vapor recovery compressors
19. CCOE Approvals
M/s. Godrej & Boyce Ltd. On Site Emergency Plan for Proposed Engineering unit along with Jetty in
CRZ area at SEZ - Dahej Report No: GCCIPL/V/GODREJ/OEP/2010-11/MAY/RMS-043/R00
Green Circle Consultants (I) Pvt. Ltd. 19
3.6 Specific safety details / provisions for handling and management
of Compressed Gas Cylinders such as hydrogen, Acetylene,
LPG, etc to be used in the process:
1. All the Compressed gas cylinders are stored properly in a dry, well
ventilated room and away from flammable substances.
2. Proper inspections of all the cylinders.
3. Empty and full cylinders are stored separately.
4. Store room should be fire proof and electrical installations
completely flameproof.
5. Acetylene cylinders are always stored upright.
3.7 Utility
The Utility block encloses Fabrication Air Compressor, Heat exchanger,
Thermic Fluid System, DG set etc.
3.8 Other Safety measures shall be provided as follow: a. Level Indication & transmitters to all storage tanks interlocked with
respective unloading and loading pumps
b. Temp transmitters with control interlock in reaction section.
c. Nitrogen inlet lines to reactors for purging with interlocked On/Off
valves
d. High/Low level alarms switches to storage tanks and interlocked with
respective pumps
e. PSV in transferring lines wherever needed.
f. Flow control valves in raw material/Product transferring lines, wherever
needed.
g. Electrical tracing wherever required with proper insulation.
h. Detection System with Alarm in plant.
i. Oxygen Analyzer in Nitrogen Line
j. Safety Vent System
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k. Safety inert lock for reactor
l. Personnel will be provided all PPE’s during working
3.9. Solvents Storage & handling
Following are the general guideline for emergency action:-
1. All storage tanks will be equipped with contact DP/non-contact radar type
level transmitters with feedback to main PLC/SCADA.
2. All storage tanks will be equipped with level switch which will stop the
respective transfer pump on activation at high level.
3. Local temperature and pressure gauges will be provided wherever
applicable.
4. Leakage or spillage of this solvent may lead to health hazards or fire /
Explosion or toxic release. So proper PPE (Personal Protective Equipments)
are provided.
3.10 Safety and Mitigating Measures SAFETY CONSIDERATIONS IN THE DESIGN Safety Considerations in the design of M/s. Godrej & Boyce Mfg. Co. Ltd, &
important mitigating measures will be provided to contain and control the
emergency are outlined below:-
General Safety Considerations:- • Adherence of international engineering standards in the design,
Construction and testing of the storage tanks, equipments and other
hardware.
• Statutory approvals of hazardous storage, waste treatment and disposal
stack emission etc.
• Storage tanks containing hazardous materials are located away form the
plant.
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• Full fledge fire protection system.
• All Storage tanks shall be located in Dykes and equipped with high and low
level indicator wherever indicated.
• Spillages and leaks from the storage tanks can be collected and transferred
out and treated for safe disposal.
• Local temperature and pressure gauges shall be provided wherever
applicable.
• The hazardous reactors are provided with seal arrangements, which will
prevent leakage of fugitive emission in case of seal failure.
FIRE PROTECTION & FIRE FIGHTING SYSTEM: - The plant will be equipped with a comprehensive fire protection system. The
fire fighting equipments will be provided as per the requirements of Gujarat
Factories Rules, 1963. Following facilities will be provided for the fire
protection.
• Fire Water Supply
• Fire Hydrant system
• Portable Fire Extinguishers
• Sand buckets, Water buckets
• Sprinkler System
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CHAPTER – 4
ENVIRONMENT IMPACT ASSESSMENT
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4.1 Introduction:
The environment elements (attributes) that are likely to be affected are
identified and categorized as air, water, land, sound, ecology, human
aspect, economics and resources.
The environment includes human being, other living creature, plants and
properties.
Amongst, these, the human beings are the most important and need
protection from any adverse impact. We have to consider two Groups:
(1) Those at work on site, and
(2) Those living and/or working in the vicinity.
The necessary instruction, training and precaution shall be taken to protect
these people against the anticipated situation by the management.
Consent from GPCB shall be obtained and necessary GPCB norms shall be
maintained.
In case of unexpected happening like collapse of tank, puncture in tank or
in pipeline etc., if not controlled, it may spread in the vicinity, may result into
its effect on human beings, other living organism, plants, properties,
depending upon the type of chemicals which contained in the tank and
gravity of incident.
4.2 Layout of the Unit The topography of the proposed plot is not flat in shape. There are no dense
natural vegetation around the site. Construction of new Industrial engineering
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unit for “Fabrication of Heat Exchanger, Pressure Vessels & Columns” along with
Jetty is proposed. The existing land use pattern is Industrial Zone and out of
235030 m2 area only 41028.90 m2 shall be used for the proposed unit of
fabrication of process related equipments. The area allotted for jetty will be
3960m2. Green belt area shall be 49207 m2. The remaining plot shall be
developed in future.
The Project Land Use Plan describes two categories of land uses: Unit for
fabrication of Heat Exchanger, Pressure Vessel & Columns is proposed in the
processing area. The unused land will be used for captive consumption in future
for further plant expansion. The space will be spare for future electrical substation
and other infrastructure facilities like internal roads, lights, STP / ETP. Design for the
same will be created at the time of actual planning for expansion of the units.
4.3 Effluent Treatment Plant
The management has provided Receiving Sump which is followed by Aeration
tank. Then the sludge developed in Aeration tank 1 will be settled in secondary
settling tank and from there it will be settled in Aeration tank II. Excess sludge shall
be dewatered by pumping to the filter press. Then further it gets transferred in
clariflocculator and then to treated effluent sump. The treated effluent pumped
from the Treated Effluent Sump through the filters (Pressure filter & activated
carbon filter) shall be used for hydraulic testing of vessels.
4.4 Noise Level
The green belt area will be developed within industrial premises and around the
periphery to prevent the noise pollution in surrounding area. Development of
green belt with carefully selected native plant species is of prime importance
due to their capacity to reduce noise and air pollution impacts by attenuation /
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assimilation.
4.5 Solid Waste Waste is an unavoidable byproduct of human activity. Economic development,
rapid urbanization & improved living standards have led to the increase in
quantity & complexity of the waste generated. Proper disposal of waste is
essential for preservation and improvement of public health.
Solid waste management: Solid waste management is one of the most essential services for maintaining the
quality of life in the plant and for ensuring better standards of health and
sanitation. Solid waste generated in the plant area can be handled under two
main categories, namely domestic wastes and industrial wastes. Effective
measures shall be taken to effectively implement the solid waste management
systems in the plant. During operation phase, generation of the solid waste shall
be around 450-500 kg/day, which shall be segregated as organic and inorganic
and handed over authorized vendor for disposal. The hazardous waste shall be
handed over to authority (BEAIL) for further disposal as per Solid Waste
Management Rules (2000) and MSIHC (Hazardous waste and Management rules
(Amended till 2008)).
4.6 Consents from GPCB:
NOC application is done. CC&A application will be done well in advance
before commencement of operations.
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CHAPTER – 5
ACCIDENT HISTORY
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5.1 Introduction
It is an engineering based unit which is going to manufacture process
equipments. The proposed industry will include infrastructure development of
the proposed area for fabrication of heat exchanger, pressure vessel &
column.
Thus, the Potential Risk can be divided in to two parts: (1) Mechanical Hazard
(2) Potential Risk of FIRE & EXPLOSION. (3) Health hazard. The handling and
use of the LPG, Nitric acid, and other compressed gas cylinders require due
precautions.
5.2 Accident Reporting System
The statutory requirements shall be fulfilled by maintaining accident register
in Form No.29, as prescribed under Gujarat Factories Rules 1963 and form
NO.21 shall also be kept for reporting to the Factory Inspectorate, as
required.
5.3 First Aid Box
The first Aid Box shall be maintained at Security cabin and all other
departments. The security staffs and operative personnel shall be trained in
First Aid.
5.4 Medical Examination
The medical examination of employees shall be carried out and records in
Form NO.32 as prescribed format shall be maintained.
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CHAPTER – 6
ORGANIZATION PLAN
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6.1 Introduction Pre - Emergency means the preparatory stage. It is the planning period and
it should come out to ensure that the plan should contain required
provisions and facilities to handle and contain the emergency successfully.
The unit has to consider worst possible scenario for emergency while
planning. Further, the unit has to develop and maintain the essential
facilities, so that emergency can be controlled & minimized the damages in
shortest period by use of existing resources.
The unit has to be ready for any possible emergency, whether it may strike
or not. Being an Engineering unit along with Chemical handling & storage
i.e. unit and knowing the hazards of the chemicals stored and handled in
the unit, response actions must be created within unit.
The structure of the plan may vary depending on the number of
employees, materials, process, and availability of recourses, location of site,
size and complexity of the unit. It should work out a plan with possibilities of
various emergencies likely to arise within unit. Further periodical rehearsal is
also to be carried out to check and examine the effectiveness, awareness
and preparedness of the plan as well as services. The emergency planning
is not a substitute for good design, operating and maintenance practices.
Therefore, these must always be followed to avoid emergency.
No plan will succeed without effective emergency organization. The
organization plan has been described the role and function of various
categories, as explained in previous Chapter. It also provides a list of
facilities with the units.
6.2 Identification of Hazards and Control Measures LPG, Acetylene, Hydrogen, Nitrogen, Nitric Acid, turpentine, HSD, Hydraulic
oil, Primer are the materials stored, handled and processed at the safe
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distance from the Transformer area. For the handling and storing of LPG,
Nitric acid, Acetylene and other hazardous materials, proper care shall be
taken.
The management shall take ample safety measures against the potential
threat of risks. However, the possibility which may lead to emergency has
been explained in previous chapters. The management is keen to maintain
highest level of safety at the unit. The various control measures on safety
have been provided in the plant.
6.3 Planning for Emergency The management shall identify the maximum credible scenario and has
planned to tackle the emergency which may strike at any time. The
following specific details in respect to create the emergency Preparedness
& awareness are listed as required into Annexure Section and Appendix
Sections.
These details shall be updated time-to-time.
(1) Participants shall be fully conversant and trained in their function or
role (As explained in for going paras)
(2) To keep and update the emergency equipments, communication
system, neutralizing agents, medicines, antidotes etc.
(3) Up-dated emergency telephone Nos. with contact persons.
(Appendix - A)
(4) Emergency control center.
(5) Emergency alarm / siren system.
(6) Marking of safe assembly point.
(7) M.S.D.S. of each hazardous chemicals (Annexure - 5)
(8) Storage, process, vessels, utility, trade waste disposal, Pollution control
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arrangements.
(9) Fire & Toxicity - Details, Gas Dispersion, Evacuation Details, Transport
and Evacuation Arrangement
(10) Medical arrangement
(11) Meteorological details
(12) Personal Protective Equipments Details
(13) Charts, Maps (Annexure 2, 3)
(14) Maintenance of Records
(15) Updation of On-site Emergency Plan to Conduct Mock Drill (Format
given in Appendix-G) and Training.
(16) Liaison with emergency services, Govt. Authorities, Voluntary
organizations, suppliers etc.
The arrangement of communication system should be foolproof so that
correct message reaches to the proper person in shortest time. The chart at
Appendix-C indicates initiation of actions and where to report.
The role and responsibilities of each acting person shall be explained in brief
with Command & Control Appendix-D during emergency period. All the
persons involved in Emergency management shall be aware of the roles &
responsibility.
The Emergency Control Room shall be fully equipped with the facilities. A
safe assembly point shall be marked with alternate safe assembly point in
case of sudden change of wind direction.
6.4 Command & Control Organization chart is given in Appendix - B, which gives organizational
structure. Chart of Initiation of Actions for the emergency plan has been
given at Appendix - C, which explains the order of command, Channel of
information flow, and actions as required during the emergency. The single
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organization structure has been created and the same shall be continued
till the emergency is over. The Safety Officer shall take the initial charge, as
Incident Controller, and he will coordinate with various agencies effectively
to combat the situation. The Office room will be used as emergency control
Room. The Assembly point shall be marked and people shall be informed to
reach at the assembly point during emergency. The Director/General
Manager will act as site main controller for the unit. On arrival, he will
supervise all activities with the help of Incident Controller (Safety Officer).
The duties & responsibilities have been defined as per below:
6.5 Incident Controller
His responsibilities include:
(1) His primary duty is to take charge at the scene.
(2) Direct all operations within the affected area giving priority to safety of
personnel.
(3) Minimize damage to property, environment and material loss by
taking necessary actions within his control.
(4) Pending arrival of site main controller, incident controller takes the
responsibility of his post and directs shut down of plant and evacuates
people, if necessary. Further, he will intimate and request to the fire,
police and medical services for required helps by giving details of
incident/accident/emergency.
(5) Ensure that all non-essential workers/staff of the affected area are
instructed to go to respective assembly point / shelter and areas are
searched for casualties.
(6) Safety Officer (Production) will perform the role of "Incident controller"
at the time of emergency period.
(7) Dy. Incident controller will perform the role as incident control till the
arrival of incident controller.
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6.6 Site Main Controller His responsibilities include:
(1) Immediately on being informed of the emergency and its location, he
will arrive at the scene & handle the situation.
(2) He will access the magnitude of the situation and decide if persons
need to be evacuated from the assembly / shelter.
(3) On his decision, he will activate the on-site emergency plan as well as
local crisis. Further, he will intimate to District Crisis Group for the further
help if condition deteriorates.
(4) To maintain continuous review of developments and access in
consultation with incident controller and other key personnel.
(5) To give information to head office and to fire bridge, police, medical,
experts, Factory inspector, GPCB and other statutory authorities.
(6) To provide advice on possible effect on areas surrounding factory
premises.
(7) To ensure that the casualties are receiving adequate attention.
Arrange for hospitalization of victims and additional help if required.
Ensure that the relatives are authorize advised.
(8) To ensure the accounting of personnel and search of missing persons.
(9) To Control traffic movement for factory premises & surrounding area.
(10) If emergency is prolonged, arrange for the relief of personnel and to
provide catering facility.
(11) To issue authorized statement to the news media and other authorities.
(12) To ensure that proper consideration is given to the preservation of
evidence. Arrange for photographs or video.
(13) To Control rehabilitation of affected areas and victims.
(14) Do not restart the plant unless, clearance or approval received from
the authorities.
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6.7 Key Personnel The key personnel shall be available at any time on duty or on call when off
or on holiday. The Role of key personnel is to perform the following
functions:
(1) Take the charge of managerial activity and support to Site Main
Controller and Incident Controller.
(2) Immediate communicate to various authority with specific details and
request for helps.
(3) Supervise and execute the work as instructed by Site Main Controller
and Incident Controller.
(4) Handle the situation & cope up the work by fair dealing.
(5) Report time to time to the Site Main Controller and Incident Controller
about your work status.
(6) Advice, Counsel, Guide, Suggest, or Caution in respect to the
handling of emergency to the SMC/IC as per your knowledge.
The List of Key Personnel & their contact numbers shall be displayed &
updated on regular bases. (Appendix A)
6.8 Essential Workers They are a task force of trained workers or expert teams to carry out specific
job or work at the time of emergency and perform the duty under
guidance of Incident Controller/Site Main Controller. The list shall be
updated from time to time.
Such work will include:
(1) Fire fighting, gas leak and spill control till a Fire Brigade takes the
charge.
(2) Shutting down plant and making it safe.
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(3) Emergency engineering work e.g. Isolating equipments, materials,
process, providing temporary by-pass lines, safe transfer of substance,
urgent repairing or replacement, electrical work etc.
(4) Provision of emergency power, water, lighting, instruments,
equipments, materials etc.
(5) Movement of equipments, special vehicles and transport to or from
the scene of the incident.
(6) Search, evacuation, rescue and welfare.
(7) First - aid and medical help.
(8) Information to surrounding factories and the public as directed by the
site Main Controller.
(9) Assistance at communication centre, casualties, reception centre,
liaison with police etc.
(10) Any special help required.
6.9 Safe Assembly Point In affected and vulnerable plant, all non - essential workers (who are not
assigned any emergency duty) shall evacuate the area and report to a
specified assembly point.
The assembly point should be clearly marked at a conspicuous place.
Assembly point must be sited in a safe place, well away from areas of risk
and least affected by the down wind direction. It may be in the open or in
a building depending on the hazard involved. The nominated person for
recording the names and departments of those reporting should be posted
there. He should have a means of communication with the site main
controller in case it is necessary to establish the where abouts of people
and to receive further instructions concerning the deployment of the
evacuated personnel.
Further, an alternative Safe Assembly point shall be marked considering the
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prevailing wind direction, incase of sudden change of wind direction.
6.10 Check Schedule The following arrangements are to be maintained and up-dated for
preparedness, of emergency purpose during pre-emergency period.
6.10.1 M.S.D.S. M.S.D.S. for Hazardous materials, which are handled and stored are given in
Annexures-5. Any updation or new information about hazardous materials
should be incorporated in M.S.D.S.
6.10.2 Weather Condition Data The Meteorological data will be updated periodically and record should be
maintain accordingly.
6.10.3 Communication System Emergency Telephone Nos. with name of contact person etc. are given in
Appendix - A. Time to time modification should be carried out for changes.
6.10.4 Emergency Control Center The Equipped Central Control Room should be in working order. The plant
layout maps, drawing, storage details" M.S.D.S, emergency operations,
manuals etc. should be kept and should be up to date. List of Emergency
telephone Nos. is also maintained up to date. The senior and expert person
shall be posted as in charge of the control room.
6.10.5 Fire Protection: To fight the fire, Systems like Fire Hydrant system, Fire extinguishers shall be
provided.
Check all the fire - fighting equipments, units and machineries for their
conditions, physical availability, workable and take necessary actions on
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replacement and maintenance, if required. Check resources of water and
keep necessary telephone Nos. of suppliers for the same. Maintain the co-
ordination with other fire - services. The water showers should be checked
periodically for working conditions. As per K-5 of schedule XXI under Rule-2
of GFR-1963, an automatic water spray / sprinkler system shall be provided.
Refer Annexure – 6
6.10.6 Personnel Protective Equipments Check all the personnel protective equipments provided at different places
for their condition, working, maintenances and replacement, whenever
required. Also keep sufficient stock of required personnel protective
equipments. Also, maintain the relation with the mutual aiders for their
supply of Personnel Protective Equipments at the time of emergency.
6.10.7 Safety Systems Check the working of all safety devices; interlock systems, safety-guard,
railing, and fencings, in position. The safety equipments should be kept
available with working condition. The safety motivation and safety training is
a continuous process and arrange such type of training, periodically.
Check the monitoring instruments, if provided, for correct working. Check
the alarm systems for its working condition. The details shall be up-dated.
6.10.8 The Medical Facilities The First Aid Boxes shall be provided at the plant area shall be adequately
filled with requisite medicines and equipments. Arrangement should be
made that at least one trained person should be available during the
working hours. The name and address with telephone No. of Doctors shall
be displayed in the Control Room along with General Hospital &
Ambulance Van facilities.
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6.10.9 Monitoring the Environment A suitable type of flameproof and portable combustible gas indicator /
sensor shall be provided and sample of various locations shall be measured
& record shall be maintained.
6.10.10 Precaution against Power Failure Provisions shall be made for the in the event of power failure, DG sets shall
be provided.
6.10.11 Maintenance of Records Keep the records of the monitoring conditions, safety systems, storage
levels, process condition, etc. and maintain the log - books, registers etc.
keep the M.S.D.S. and onsite emergency plan with required details.
6.10.12 Exercises/Mock Drill/Rehearsal Organize the periodical mock drill/ rehearsal as per suggested format on
emergency situation so as to keep up preparedness & awareness to over
come shortcomings. Give prior information with reasonable time to the
emergency services and public for proper response & training. Record the
deficiencies of the system during the trial and take appropriate action to
improve the effectiveness of the plan in terms of preparedness and
response. A format on such mock drill is appended in Appendix-G.
6.10.13 Potentiality on Liaison Keep constant liaison with mutual aiders, fire services, police department,
medical services, statutory authorities, District administration, during pre-
emergency situation. Keep liaison with local Crisis Group and District Crisis
Group.
6.10.14 Public Education
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Efforts to be made to educate the surrounding public about the existing
hazards of the plant, the possible emergency actions and the precautions
required to be taken in such condition. Leaflet containing such details can
be distributed amongst the public. The training program can be arranged
in the school, public institution. It can be circulated to news media, TV,
Video- channels, newspapers etc.
6.10.15 Training (Internal) With the help of efficient plant supervisors, inspectors, the education &
training of the workers to be kept alive all the time to ensure good
housekeeping, discipline and display of safety slogans, operative
instructions and motivation on safety. All the persons from the emergency
services, organization is to be trained to response the emergency.
6.10.16 Siren Testing The siren shall be checked & tested periodically at certain intervals so that
awareness & preparedness can be checked.
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CHAPTER – 7
EMERGENCY PROCEDURE
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7.1 Actions during Emergency It is not possible to include and discuss every action, which should be taken
during emergency; It is also not possible to describe entire actions on
emergency situation. The basic principle of handling emergency is to rely
upon person, who has the knowledge and experience to assess the
situation and give direction as per the objectives as quickly as possible.
However, the aim is to control the situation by safest way in limited time
within available resources. Further, it should handle with care so that loss of
life, property and environment is minimized. In short, the plan should be
successfully complied with.
7.2 Sequential Actions during Emergency
Various actions are required to be initiated according to the situation.
However, some systematic codification is required to control such
emergency, the following sequential actions may be helpful to contain
emergency.
7.2.1 Incident
There are possibilities of various types of accidents or mishaps occurring in
the factory/premises. Most are of minor type, while few cases may be major
type. Some times there is no single incident during the life span. However,
when any incident occurs, it cannot be distinguished immediately, the
subsequent development or seriousness of such occurrence is required to
handle safely.
It should be general practice that any person noticing the
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accident/fire/explosion/mishap at the site, should shout "FIRE", "FIRE" or
"HELP", "HELP" and such message should reach to Supervisor/Shift Engineer/
Senior Person of the unit. This way first information will reach to responsible
person.
7.2.2 Responding Actions
It is said that root cause should be removed immediately. Similarly, if any
incident takes place in the premises it should be tackled with available
resources, it should be so responded that it is contained immediately before
spreading. If the incident looks severe and cannot be controlled by simple
efforts, the Shift Engineer or senior person should rush to the place and try to
control by using resources at the site.
Further, if it is uncontrollable even after using own resources, immediately
call for further help from outside e.g. mutual aiders, fire-brigade etc. He
takes over as incident controller & initiate following actions.
Sound the siren or ring the emergency bell.
Continuous responding actions, with the use of other helps.
Call the higher authority / Site main controller.
7.2.3 On-Site Emergency On arrival, of Incident Controller/Site Main Controller, he assesses the
situation and handles the incident as site crisis. The incident can be said as
On Site-Emergency.
He will,
Activate the fire brigade, police, mutual aiders and essential workers,
expert persons.
Mobilize more resources from the neighboring industries and other
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available resources.
The messages regarding prevailing situation to concerned authorities,
agencies, neighbors etc. will be communicated through the control
room.
Non-essential person will rush to safe shelter and their roll call to be
taken.
Try to contain by using all available resources within his command.
Now, if situation is uncontrollable by the management of the unit, he should
immediately call the local crisis group to handle the situation.
7.2.4 Off-Site Emergency:
a) Local Crisis Group: The Chairman of Local Crisis Group with committee members handles the
situation by responding actions. The Chairman of the Committee pools the
entire local resources at site and tries to mitigate the situation. However, if it is
presumed that the magnitude of the event is such high that it is
uncontrollable by the Local Crisis' Group, than The District Crisis Group will be
intimated to handle the emergency.
b) District Crisis Group: The Chairman, along with members of District Crisis Group takes over the
charge of escalating situation. After, assessing the situation, he declares the
"District Crisis" in action. To combat the emergency, he mobilizes the
emergency services; and handles the situation as off-site emergency.
The Central Control Room will activate and communicate the messages to
the various District resources. Thus, all the resources from entire District will be
called on and diverted to the scene and mobilize to control the incident in a
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efficient & coordinated way.
7.2.5 Messages: While conveying the messages regarding the incident, the following details
should be incorporated.
Brief description of incident.
Type of help required & direction.
Chemical involved & quantity.
Action immediately taken.
Development of the incident.
The Appendix - F indicates the format for emergency call/meeting.
7.3 Emergency Actions (General) 1. On receiving information, the control room activates and establishes
the contact with Key Personnel, Essential workers, services, agencies &
authorities, urgently.
2. The essential workers, who are responsible to carry out certain specific
functions, have to work immediately.
3. The non-essential workers should go to the assembly center.
4. Ensure the cordoning of the incident area.
5. Spray the water on the flammable storage tank, even if not caught
under fire.
6. Consult the experts for responding the emergency, if required.
7. Give authorized information to Press / Public.
8. Arrange to remove the flammable, dangerous materials, cylinders etc.
at safe places and try to isolate from fire.
9. Provide all assistants to fire brigade to control spreading of fire.
10. Rescue the trapped personnel.
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11. Eliminate possibility of re-ignition or Explosion.
7.4 Emergency Communication:
Anyone from Factory, if notice or observe any type of fire, explosion, gas cloud,
leak, toxic release,
He has to -
Inform security officer, who will then actuate fire Siren or emergency
alarm after consultation with authorized person
In case of injury, inform Assistant Manager.
Get back to your normal work station if safe or else report to the
nearest emergency control point.
7.5 Action Plan for Emergency in Charge (IC/SMC)
(On receiving information on incident/Accident)
Immediate rush to the scene/place
Assess the situation & start remedial measures
If situation is more severe than activate emergency control center, initiate
following action;
o Communications with top management ~ Start responding
actions
o Preserve evidence.
o Organize investigation team
If necessary set up of forward control centre and start following
immediate actions;
1. Inform security person to sound fire siren or emergency alarm.
2. Start emergency action with the help of key personnel and
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essential workers.
3. Cordon incident/accident area and restrict unauthorized entry.
4. Ensure immediate starting of fire fighting system like fire hoses,
monitors, sprinklers system, sprays, and neighboring equipments.
5. Ensure shut down of various plants in right sequence.
6. Communicate with top management / head office.
7. Communicate with statutory bodies like Factory Inspector,
Insurance, and District Magistrate etc.
8. Issue authorized statement to news media.
9. Search of affected area for casualties.
10. Call mutual aiders and inform local crisis group.
11. Preserve evidence; arrange photographs, and logging of
events.
12. Before ordering the re-entering check that it is safe for.
13. Do not restart till steps taken to prevent the returns recurrence.
7.6 Action Plan for In-Charge of Emergency Control Center i.e.
Communication Officer
(On Hearing Alarm Emergency information)
Proceed to Emergency control central and perform the duties.
Follow the line of action with IC/ SMC.
Inform fire brigade / police / mutual aiders.
Ask key personnel & essential worker to report IC/SMC.
Inform all non-essential workers to reach the assembly point.
Inform neighboring factories, companies, units.
Communicate with statutory bodies like Factory Inspector, Insurance
Agency, Police Authority, Magistrate etc.
Arrange to rescue of missing & trap persons.
Arrange to search affected area for causalities.
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Ensure cordoning of affected area.
Instruction to emergency vehicle, e.g. fire tender, etc.
Inform surrounding population with the help of police.
Requisition cars, buses, ambulance, if required.
Additional ambulance and treatment for victim.
Reserve injuries, hospitalization for victim. (e.g. Burns, causalities)
Inform relatives of victims
Evacuation of neighboring population, if required.
Check rehabilitation of victims.
7.7 Action plan for Key Personnel and Essential Workers
(On Hearing Fire/Emergency Alarm)
Inform security officer of location and nature of emergency.
Minimize consequence by :
o Eliminating ignition source
o Shutting down plants as quickly as possible
o Transferring flammable material to safer places
o Switch on water sprays / sprinklers
o Stopping of loading unloading operations
o Removal of tanker lorries from the unit
o Cordoning of area / incident place .
o Monitoring atmosphere water channels for further action.
o Operation of fire fighting equipments, foam type extinguishers.
o Ensure that fire pumps are in working order.
o Provide engineering assistance to emergency in charge
o Other duties as allocated by IC/SMC.
7.8 Action plan for Security Guards/ Officer
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Inform emergency in-charge by telephone
On receipt of information in case siren is not actuated, sound/blow the
siren, if directed by IC/SMC
Depute security guards to control traffic around area of emergency
and cordoning of incident area.
Keep visitors out & prevent unauthorized entry
Control Traffic of gate / inside and outside
Await further instructions from emergency center/in charge
Inform others as directed by emergency center/ in charge
Evacuation of site - Partially or full
Search affected areas for causalities
Eliminating ignition sources
Removal of tank lorries from unit
Evacuation all non essential workers to the assembly point and Head
Count.
Guide the mutual aiders, fire brigade, govt. officers, emergency
vehicles, etc. for safe way towards emergency incident and safe
parking.
7.9 Action Plan for Workers/Officers /Contractor
Upon hearing emergency siren/alarm
Leave site immediately by safest route to assembly point.
Proceed at right angels to wind direction.
Do not re-enter site unless directed personally or via PA system.
Assist in head count at assembly point
Inform contractor personnel to stop work upon hearing fire / gas alarm
and ask to assemble at the main security, gate.
Do not go to incident place unless specifically instructed by
Emergency in-charge.
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Avoid Panic
7.10. Discipline
The plan assumes certain discipline at site during emergency, as follows;
Do not get panicky.
Do not approach the site of incident, as a spectator.
Do not Engaged telephone unnecessary;
Do not move about unnecessary.
Do not approach unnecessarily for information or more inquiry.
Arrange medical first aid care to the injured.
Do not allow unnecessary crowd nearby incident.
7.11 Shut down Procedure
We cannot neglect the adverse effect of the running plant during emergency.
Therefore, it is advisable and safe that the safe shut down procedure should be
adopted, if running. First of all main electrical supply line should be cut-off.
Similarly, the pipelines carrying flammable gas, liquid or chemicals are to be
isolated immediately. If reaction in the any vessel is in process, it should be
stopped & safely shut down.
Arrange to transfer or remove the flammable, toxic, dangerous, explosive,
poisonous materials, goods, cylinders, drums etc. to safe place or try to isolate
from the fire.
Arrange the water shower on flammable storage tanks to keep it in cool
conditions, if near the fire.
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The shut down procedure should be laid down in the process manual, which will
be useful during such emergency.
7.12. Post Emergency
The following actions are suggested as per prevailing situation depending upon
the level of emergency.
1. In Case of On-Site Emergency
After controlling the emergency and ascertained for no possibility of re-
occurrence, the management will indicate the following actions.
1. Declare termination of Emergency & blow the siren accordingly.
2. Disclose the authentic statement on incident to the authority &
news media.
3. Collect & preserve the documents, records, instruments, evidence
etc. on incident.
4. To set up the internal enquiry committee, appearing the internal or
external expert person.
5. Cleaning work after obtaining the permission from Authority.
6. Preparation of restarting the process work.
7. Detailed related work & procedure, as described below;
o Sound the emergency clear siren.
o The rehabilitation work will start in the affected area.
o To ensure that all fires are extinguished and there is no risk of
re-ignition, before starting work.
o To ensure that there is no chance of secondary explosion.
o Do not disturb wreckage and debris except to rescue the
injured or recover bodies, until permitted to do so by
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statutory authority.
o All victims, dead or alive, are' systematically identified and
keep the records accordingly. Give information to their
relatives, if asked.
o Record all relevant information.
o Take photograph / video or make suitable sketches of the
incidence.
o Report the accident / incident, with details, to the statutory,
authorities, if not informed.
o Permission for restarting is required to be obtained from
statutory authorities.
o Keep registers for recording the entries, details, inventory, list
of persons etc. & preserve the all the documents, log books,
maps, registers all records taken from the site.
o Keep the record of help; Co-operation, Mutual aiders sought
from others & write thanks giving letters to them.
o Arrange the compensations to the affected persons, injured
persons, dead etc. as per circumstance and if applicable,
keep the records accordingly.
o Estimate the expenses incurred during the emergency.
o Estimate the various expenses under different head &
prepare the total expenditures statement.
o Appoint the internal committee to investigate into the causes
of the accident / incident, if necessary and get report.
2. In Case of Off-Site Emergency Plan: Being apex body during the Off-Site Emergency Period, the Crisis Group will
get the report from emergency services for safe rehabilitation and Pollution
Control Authority for safe environment condition and then decide the
declaration of termination of emergency. The authority may constitute the
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enquiry committee, by appointing inclusive of expert persons and ask to
submit the said report within specified period. Then, Crisis Group will ask the
explanation from management on the said report. On winding up the
actions, the Crisis Groups will permit the management to clean and re-
starting the work for process and other related work as mentioned in above
Para 7.12.1- point No. (7).
7.13 Corrective Actions
The accident is eye opening toward the irregularities. Similarly, the occurrence of
major emergency directly indicates the shortcomings or weaknesses of the plant,
handling method, transportation, working procedure, storage procedure, unsafe
condition or unsafe actions etc. It may reveal from the investigation or
recommendations of the committee.
Necessary corrective steps / actions in light of the investigation report or findings
are required to be taken to ensure that such emergency accident does not
repeat. Therefore, modification, alterations, changes in operation, instruction,
process, and handling are suggested, should be implemented accordingly to
make working safe.
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ANNEXURE SECTION
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ANNEXURE SECTION
ANNEXURE NO. CONTENTS PAGE NO.
1. Identification of factory
2. Location Map
3. Plant Layout
4. Storage Hazards & Controls
5. List of M.S.D.S
6. Fire Hydrant Layout
7. External phones
8. Emergency Instruction Booklet
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ANNEXURE -1
IDENTIFICATION OF THE FACTORY
Sr.
No. Descriptions Details
1 Name & Address of Unit
A Unit for fabrication of heat exchanger,
pressure vessels & columns at Godrej & Boyce
Mfg. Co. Ltd Taluka - Vagra, District-Bharuch,
State-Gujarat
2 Regd. Office Address
Godrej & Boyce Mfg. Co. Ltd.
Pirojshanagar, Vikhroli,
Mumbai – 400 021.
Mobile: 98205 22010
3 Telephone No. (022) 67962051
4 Fax No. (022) 67961501
5 TELEX -
6 E-mail [email protected]
7 Name & Address of Occupier
of Factory
Mr. Anil G Verma
Executive Director cum - Head ( P&A )
Godrej & Boyce Company Ltd.
Plant-12,Corporate Personnel Department
Pirojshanagar, Vikhroli,
Mumbai - 400 079, MS, India
8 General Manager of Factory Mr. Nitin S Palan
9 Finished Products Fabrication of various process equipments like
heat exchangers, pressure vessels & columns.
10 Process involved
1. Inspection & Marking
2. Machine cutting & gas cutting
3. Cold rolling
4. Welding
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5. Fabrication
11
Hazardous Chemicals
Hydrogen
Acetylene
Liquefied Petroleum Gas
a) As per listed under schedule-1 of Rule 68-
J of GFR 1963 (1995).
b) The quantities of the identified hazardous
chemicals under MSIHC Schedule-I are
much below the applicable / permitted
threshold quantities as per Schedule-II.
12
Factory License from Factory
inspection Department, Gujarat
State
Under Process
13 License from Department of
Explosives -
3.3 Details of Units (Continue…)
Sr.
No. Descriptions Details
14 GPCB Consent
Sr.
No.
Consent Consent
No.
Validity
1 CC&A -- --
15 Facility/System
(1) All electrical equipments, writing &
fitting shall be flameproof type.
(2) Provision of D.G. Set to meet
emergency.
(3) Provision of water storage.
(4) Water sprinkler system shall be installed
in the plant.
(5) Provision of portable fire extinguishers &
fire buckets.
(6) Well ventilated storage area.
(7) Provision of Earthing
(8) Smoking is prohibited
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(9) Trained & Experienced persons.
(10) Arrangement of Siren/Bell/Messages
(11) Auto control, Control Room, Internal
Phone.
(12) Communicator system, Mobile phone,
Fax, E-mails, etc.
(13) Displayment of Notices
(14) Color Code system for Pipe Lines.
(15) First Aid Trained Person.
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ANNEXURE – 2
LOCATION MAP
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ANNEXURE – 3
PLANT LAYOUT
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Annexure -4 STORAGE HAZARDS & CONTROL
TABLE 1 STORAGE FACILITY FOR RAW MATERIALS
Sr.No Raw Material No. of container & size (MT)
Pres--sure Kg/cm2
Temp (˚C )
Total Quantity
(MT)
Type of Hazard Consumption MT/
annum No. Size
1 Carbon Steel N.A N.A N.A N.A 810 MT Non-combustible 9720 2 Stainless Steel N.A N.A N.A N.A 40 MT Fumes / gases produced from
welding or burning operations 480
3 Mild Steel – 410
N.A N.A N.A N.A 365 MT Fumes / gases produced from welding or burning operations
4380
4 Other metals N.A N.A N.A N.A 135 MT May be Flammable 1620 5 Oxygen 145 7 m3 150
kg/cm2 Ambient 1015 m3 Non flammable 181200
6 Argon 40 7 m3 150 kg/cm2
Ambient 280 m3 Non Flammable 68760
7 Hydrogen 3 5.5m3 150 kg/cm2
Ambient 15.6 m3 Flammable gas & Asphyxiant
600
8 Nitrogen 50 7 m3 150 kg/cm2
Ambient 350 m3 Non Flammable 4380
9 Acetylene 50 7 m3 16-18 kg/cm2
Ambient 350 m3 Explosion 24876
10 Carbon dioxide
30 30 Kg 150 kg/cm2
Ambient 900 Kg Non Flammable
38880
11 Thinner 30 20 L N.A Ambient 600 L Flammable 21600 12 Hydro Fluoric
Acid 10 35 Kg N.A Ambient 350 Kg Corrosive in nature 600
13 Nitric Acid 17 35 Kg N.A Ambient 595 Kg Health hazard 5160
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14 M3 Degreaser 100 5 Kg N.A Ambient 500 Kg Slightly pungent 240 15 Primer 10 20 Lit N.A Ambient 200 L Fire & health hazard 2160 16 Other paints 100 20 Kg N.A Ambient 2000
Kg Health hazard 37740
17 Hydraulic oil 10 210 L N.A Ambient 2100 L NA 24300 18 Grease 1 5 Kg N.A Ambient 5 Kg NA 18 19 Turpentine 5 20 L N.A Ambient 100 L Flammable 3240
Details of Fuel Consumption
SR. NO. NAME OF FUEL QUANTITY / MONTH
1 LPG 60700 KG 2 CNG 28000 SCM 3 HSD 7500 LTR
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STORAGE FACILITY FOR HAZARDOUS CHEMICALS
Sr. No. Name Of Chemical Type of Storage Storage Quantity Type of Hazard Hydrogen Cylinder 110 CMT Flammable gas & Asphyxiant
Acetylene Cylinder 110 CMT Explosion
1 Flammable Gases
LPG Bullet/Cylinder 6 Ton Flammable
HSD Tank 1250 ltrs Flammable liquid Nitric Acid Carboys(35 lit) 300 kg Health hazard
Primer Tin Container 300 ltrs Fire & health hazard Other paints Tin Container 300 ltrs Health hazard
Thinner Tin Container 920 kg Flammable
2 Flammable Liquids
Turpentine Tin Container 300 ltrs Flammable
Note: The quantities of the identified hazardous chemicals under MSIHC Schedule-I are much below the
applicable / permitted threshold quantities as per Schedule-II.
Material Safety Data Sheet given in Annexure – 5.
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Annexure- 5 LIST OF MSDS
Sr. No. Hazardous Chemicals
1 Hydrogen
2 Acetylene
3 LPG
4 Nitric Acid
5 Thinner
Note:- MSDS will be attached in the final copy of onsite plan
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Annexure - 6
FIRE HYDRANT LAYOUT
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ANNEXURE -7
EXTERNAL PHONES
Person available on this Phone Phone No.
Residence
Sr.
No.
Name &
Address of the
dept/Service/
Person
(including
external
emergency
services)
External Internal
Name Designation Services
expected
under On-
site/Off-
site
emergency
plan
Phone No.
(External)
Address
1 2 3 4 5 6 7 8 9
Please See Appendix – A
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ANNEXURE -8 (1 OF 2) EMERGENCY INSTRUCTION BOOKLET
Sr. No.
Role to be Played as (Name emergency
designation)
His emergency duties /Function Also refer (other relevant document
of the factory)
He should report at (the incident place or
control room) 1 2 3 4 5 1. Rush to accident site
1. Ask the field operators to close the required values & operation/process at accident site.
2. Assess the scale of emergency. 3. Take necessary actions to activated the emergency procedure 4. Ensure safety of personnel and arrange to issue all required personal
protective equipments 5. Alert the hospital authorities and arrange for necessary antidotes 6. Direct key personnel & Essential workers to carry out their duties to control
the situations 7. Ensure that out side emergency services have been called in. 8. Decide for continuing the operation of the plant 9. Ensure affected area is cordoned off 10. Ensure that all non-essential workers in the affected area evacuate and
assemble to safe assembly point/ shelter and arrange for roll call. 11. Brief site main controller and intimation to local crisis Group 12. Preserve all evidence for subsequent fact finding investigating the matters
1 Incident Controller (I.C.)
13. Provide necessary information to authorities who investigating the matters
M.S.D.S On-Site E-Plan,
Operational Mutual
Emergency Control Center, Site Main
controller, Local Crisis Group
1. Immediately rush to the scene on knowing about the emergency. Consult incident controller, get details from emergency control centre and assessing situation declare emergency
2. Ensure for mutual aid & outside help and intimation to District Crisis Group 3. Ensure availability of all the important personnel, key person 4. Shut down and evacuate 5. Ensure that the injured or casualities are receiving adequate attention and
relatives are advised /informed 6. Ensure accounting of personnel 7. Intimate to Local/District Crisis Group, and other statutory authorities 8. Continuously review possible developments
2 Site Main Controller
(SMC)
9. Direct for Vehicle, transportation, medical, fire fighting, leak-control, traffic
M.S.D.S On-Site E-Plan,
Operational Mutual
Emergency Control Center, Central Main
controller, District Crisis Group
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control 10. Arrange for relief of personnel 11. Issue authorized statement to news and media 12. In Case of escalation arrange to warn & necessary information to nearby
population. 13. Take action for rehabilitation of victims at Hospitals 14. Arrange for chronological records on emergency to be maintained.
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ANNEXURE -8 (2 OF 2) EMERGENCY INSTRUCTION BOOKLET
Sr. No.
Role to be Played as (Name emergency
designation)
His emergency duties /Function Also refer (other relevant document
of the factory)
He should report at (the incident place or
control room) 1 2 3 4 5
1. Rush to the site, with required equipments & gadgets and act as assigned their respective duties for handling emergency in consultation with IC & SMC
2. Will take other directives form IC & SMC 3. Direct and help the mutual aiders, outside agencies, traffic vehicles etc.
according to the instruction 4. Do not leave the place of incident unless permitted. 5. Do not take any decision on your own. If any self generated idea for control
measures first consult with IC/SMC then put in action, as per discussion.
3. Key Personnel
(K.P.)
6. Keep proper and exact all records of relevant matters pertaining to emergency/incident
On-site E-Plan M.S.D.S.
Incident Place Emergency Control
Center Incident Controller, Site Main Controller
1. On hearing siren, immediately rush to the scene of incident and act according to directives given by IC/SMC or assigned duties role of emergency plans.
2. Assist & help fire gighting, leak control, first aid, closing valves or supply or other work
3. Do not take any decision on your own. However, any good idea pertaining to handle emergency effective, get consulted with IC/SMC & do accordingly.
4. Do not act which will duplicate the same work & without wasting of tiem & delay, carryout your assigned function with personal protective equipments.
5. Do not leave the place of incident without permission.
4 Essential Workers (E.W.)
6. Report all matters pertaining to emergency to IC/SMC
On-site E-Plan M.S.D.S.
Incident Place Emergency Control
Center Incident Controller, Site Main Controller
1. On hearing emergency siren take instructions form shift in charge or supervisor and act accordingly.
2. Assessment at safe assemble points if situation demand or check wind direction and rush to the safe place.
3. Do not get panicky. 4. Do not obstruct any activity being done for controlling emergency. 5. Do not engage any phone to know about emergency 6. Be alert to hear clear instruction from authority
5 Non-Essential Workers
7. Ensure your presence and help to count numbers
On-site E-Plan M.S.D.S.
Incident Place Emergency Control
Center Incident Controller, Site Main Controller
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APPENDIX SECTION
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APPENDIX SECTION
APPENDIX CONTENTS PAGE NO.
A Emergency Telephone No.
B Organizational Chart
C Chart of Initiation of Actions
D Command & Controller Level – I & II (Onsite)
E Disclosure of Information to the Public
F Procedure for Meeting Emergency
G Rehearsal/Simulation/Mock Drill
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Appendix - A
EMERGENCY PHONE Nos.
Sr. No. Service Phone no.
1 Police Control Room 100
2 Fire station – Control room 101
3 Ambulance room, Bharuch 102
4 Civil Hospital , Bharuch 243523
5 D.S.P., Police Dept. 243320
6 Fire station, Bharuch 240093
KEY PERSONNELS TO BE CONTACTED DURING EMERGENCY
Sr. No. Name of Key Personnels Contact no
1. Mr Nitin Palan (M)09820444897
LAN 0226796 5566 2. Virendrasinh Bhadola
(M) 09819959618
LAN: 0226796 5530
3. Cyrus Shroff
(M) 09820550459
LAN: 022 6796 2041
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Appendix – B ORGANIZATIONAL CHART
ORGANIZATIONAL STRUCTURE
Dahej ROLE General Alternative
Chief Emergency Controller Plant incharge
Site Controller Safety officer
Shift In-charge
Team - A (Fire fighting) Shift Production Team
Team- B (Support Team) All Maintenance
Team - C (Rescue Team) All Trained First Aiders
Advisory Team All QA staff
Communication Team Logistics / Security Team
EMERGENCY MANAGEMENT CHART
CHIEF CONTROLLER PLANT INCHARGE / SHIFT
SITE CONTROLLER SAFETY OFFICER. / SHIFT
SUPERVISOR
COMMUNICATION TEAM
ILE – DLE /
ADVISARY TEAM CP - QA
Team-A Fire Fighting
All plant
Team-B Supporting Team
Maintenance
Team-C Rescue Team Trained first-
Task completion
Report to ECC
Investigation &
Report preparation
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APPENDIX – C
CHART OF INITIATION OF ACTIONS
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APPENDIX – D
COMMAND & CONTROLLER LEVEL – I &II (ON SITE)
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Appendix – E
Disclosure of Information to the Public The arrangement to disclose the following instruction is to be made by the management to educate the surrounding public about the hazards existed at site and explain the precautionary measures and actions to be taken during an emergency if arises. SUMMARY: The management has taken ample step to run the installation safely. However, the emergency may strike at any time due to unavoidable circumstances and beyond control of management. Fire would be major emergency, which may affect people and property outside the installation/unit. The declaration of emergency will indicate by Siren. It will sound differently depends upon the type of emergency arises. The public in vicinity shall be take prompt action to protect themselves as instructed. The following suggestions/ actions have to be implemented immediately, in case of major fire or any emergency arise in the unit. Follows the do’s and don’ts instructions s given below:
• Shut down open flame, gas, electrical instruments etc in the emergency area. • Do not smoke. Do not light Bidi/Cigarate/Lighter etc. • Do not go near the incident and don’t allow others. • Be calm, don’t get panic. • Shut down the windows, doors etc. and seat open ground or terrace. • Rush to the safe shelter as instructed by authority • Ascertain the emergency and hear the correct instruction. • Do not approach unnecessarily to the incident for information or any inquiries. • Do not allow unnecessarily crowd nearby incident place. • Do not believe in rumors. • Follow the instructions and convey to others accordingly during an emergency. • Once emergency is clear, all clear sirens will blow and, then you can start your routine
work. • During an inquiry, give your statement on emergency as experienced by you when you are
asked by higher authority. • Co-operate, help and assist the person/authority handling the emergency and rescue
operation.
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Appendix – F
Procedure for Meeting Emergency _____________________________________________________________________
ABSTRACT Abstract of procedure for meeting emergencies as prescribed under Gujarat Factories
Rules, 1963 (95)
Para 23 of Part – I – of Schedule XIX of G.F.R. 1963 (95)
1. Act, shall arrange to identify all types of possible emergencies that could occur in
the Unit. The occupier of every factory carrying out the works covered in the first schedule of the processes during the course of work or while carrying out maintenance work or repair work. The emergencies so identified shall be reviewed yearly;
2. The occupier shall formulate a detailed plan to meet all such identified
emergencies including arrangements for summoning outside help for rescue and fire fighting and arrangements for.; making available urgent medical facilities.
3. The occupier shall send the list of emergencies and the details of procedures and
plans formulated to meet the emergencies, to the Chief Inspector, of Factories. 4. The Occupier shall arrange to install distinctive and recognizable warning
arrangements to caution all persons inside the plant as well as the neighboring community, if necessary, to enable evacuation of persons and to enable the observance of emergency procedures by the persons who are assigned emergency duties. All concerned must be well informed about the warning arrangements and their meaning. The arrangements must be checked for its effectiveness every month.
5. Alternate power supply arrangements shall be made and inter-locked with the
normal power supply system so as to ensure constant supply of power to the facilities and equipment.
6. The occupier shall arrange to suspend the further process work in a place where
emergency is established and shall forthwith evacuate all persons in that area except workers who have been assigned emergency duties.
7. All the employees of the factory shall be trained about the action to be taken by
them including evacuation procedure during emergencies.
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8. All emergency procedures must be rehearsed every three months and deficiencies, if any, in the achievement of the objectives shall suitably be corrected.
9. The occupier shall arrange to have ten per cent of the workers trained in the use
of First Aid, Fire-fighting appliances and in the rendering of specific First Aid measures taking into consideration the special hazards of the particular process.
10. The occupier shall furnish immediately, on request the specific chemical identity of the hazardous substance to the treating physician' when the information is needed to administer proper emergency of first-aid treatment to exposed person.
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Appendix – G Rehearsal/Simulation/Mock Drill
1. SUBJECT:
Exercise / Rehearsal/Simulation on ON-SITE-EMERGENCY PLAN 2. AIM:
It is necessary that all aspect of emergency plan be tested often to ensure that they carry out their responsibility & function as specified and in particular to: Test the response from workers, emergency services, and other responsible persons. Test and evaluate the interaction of various agencies / authorities involved and ensure that all components are properly coordinated. Evaluate the available resources, equipments, its effectiveness, accuracy etc. Gain experience.
3. AUTHORITY OF EXERCISE I REHEARSAL:
The Director / Occupier is required to assume responsibilities & make decisions as seen to be legitimate.
4. TABLE DISCUSSION:
The first part of exercise is 'Table Top' exercise to test that emergency. Plan does not interrupt the day-to-day running of their concerns. This will identify the difficulties involved and practical approaches. The Scenarios will be decided and consideration should be given to live practical involving all concerned at suitable intervals, in addition to those of a theoretical nature.
5. BLUE PRINT:
A blue print is prepared as guideline to act, accordingly in a selected scenario. It is advised to give CODE NAME for identification of each emergency exercise. Further, Identification mark should be given to each emergency services, observers, inviters, connected persons etc.
6. NATURE:
Origin, Date & time, location and Duration of exercise etc. will be predecided in particular manner.
7. AFFECTED AREA:
It is the indication of the spread of disaster. This will be reflected in Blue print & give details of original place, units, surrounding identities, villages, roads, locations etc.
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8. CONTROL ROOM:
A control room will be established for exercise, where communication & other activities can be performed.
9. PREPARATION STAGE:
The responsibilities & duties will be allotted to each group, services and involving all personnel. Educative meeting will be arranged to explain the role of each participant. Blue print, scenarios and arrangements will be discussed at large. Charts, maps, Posters, Banners etc. will be prepared for good performance.
10. SEQUENTIAL ACTIONS:
The whole exercise /rehearsal will be arranged in sequential actions as per on-site emergency plan. Thus actual exercise will be conducted, as rehearsal.
11. OBSERVATIONS:
The outsiders / third party will perform the role of observers and they will submit their reports on various site- observations with shortcomings & good features.
12. DE-BRIEF MEETING:
On completion of exercise, a de-brief meeting will convene to discuss the conducted exercise, give views on performance of each areas; explain difficulties, resources, limitation, planning etc. All these observations, with corrective steps will be noted & reports will be prepared.
13. PHOTOGRAPHS, VIDEO & PRESS COVERAGE:
Photography, vediography will be carried out for the work performed. The reports of such exercise will be sent to press for coverage. Leaflets and Pamphlets will be issued to the public to educate them for the emergency.
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Annexure XIX
Odor Management Plan– Issues related to Treatment Plant Performance
The potential release of odors is a major concern of the public relative to
construction new facilities. Thus, the control of odors has become a major
consideration in the design and operation of waste water collection,
treatment, and disposal facilities, especially with respect to the public
acceptance of these facilities. The importance of the odors in the field of ETP
can view by following means,
1. The types of the odors encountered
2. The sources of odors
3. The movements of odorous gases
4. Strategies for odor control
5. Odor control methods
6. The design of odor – control facilities
Types of odors
The Principal types of odors encountered in waste water management
facilities are Ammonia (NH3), Chlorine (Cl2), Hydrogen sulfide (H2S), Sulfur
dioxide (SO2), and Methyl Amine (CH3NH2) etc. with few exceptions,
odorous compounds typically contain either sulfur or Nitrogen. The
characteristic odor of organic compounds containing sulfur is that of
decayed organic material. Gas chromatography has been used
successfully for the identification of specific compounds responsible for
odors. Unfortunately, this technique has not proved as successful in the
detection of odor because of many compounds that may be involved.
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Sources of odors:
Table 19.1: Sources of odors
Location Source/Cause Odor
Potential
Waste Water –Collection System
Air release Valves
Cleanouts
Access Part (man holes
Accumulation of odorous gases
released from wastewater
High
Industrial waste water
discharges
Odorous compounds may be
discharged to waste water collection
system
Variable
Raw Wastewater
pumping station
Wet well/Septic raw wastewater , solids
and scum deposits
High
ETP facilities
Head works Release odors gases generated in the
waste water collection system due to
turbulence in hydraulic channels and
transfer basins
Screening facilities Putrescible matter removed by
screening
Preaeration Release odors gases generated in the
waste water collection system
Grit removal Organic matter removed with grit
Flow – equalization basins Basin surfaces/septic conditions due to
accumulation of scum and solids
deposits
Septage receiving and
handling facilities
Odorous compounds can be released
at septage receiving stations, especially
when septage is being transferred
Side stream returns Return flows from bio solids processing
facilities
High
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Location Source/Cause Odor
Potential
Primary clarifiers Effluent weirs and troughs/turbulence
that releases odorous gases. Scum-
either floating of accumulated on weirs
and baffles/putrescible matter. Floating
sludge/septic conditions
High
/Moderate
Fixed film processes (TF or
RBCs)
Biological film due to insufficient
oxygen, high organic loading or
plugging ; turbulence causing release
of odorous material
Moderate/Hi
gh
Aeration basins Poor Mixing, Inadequate DO, solids
deposits
Secondary clarifiers Floating solid/excessive solids retention
Low
/Moderate
Sludge and bio solids facilities
Thickener, solids holding
tanks
Solids deposits, odor release by
turbulence
Aerobic digestion Incomplete Mixing
Anaerobic digestion High sulfate content, leakage of H2S
Sludge storage basins Lack of mixing, formation of scum layer
Mechanical dewatering
by belt-filter press,
recessed plate-filter
press, or Centrifuge
Cake solids; chemical addition,
ammonia release
Moderate/Hi
gh
Sludge load out facilities During transfer of bio solids from storage
to transfer facilities
Composting facilities Insufficient aeration and ventilation
High
Alkaline stabilization Reaction with lime Moderate
Sludge drying beds Drying solids/excess putrescible matter
due to insufficient stabilization
Moderate/Hi
gh
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The movements of odorous gases
Odorous gases are denser than air so it tends to transfer at the point of
generation (e.g. sludge thickening facilities, sludge storage lagoons). In some
cases odors have been detected at distances of up to 25 km from their
source.
Strategies for odor management
1. Control of odor causing wastewaters discharged to the collection
system and treatment plant that creates odor problems
2. Control of odors generated in the waste water collection system
3. Control of odors generated in the waste water treatment facilities
4. Installation of odor containment and treatment facilities
5. Application of chemicals to the liquid phase
6. Use of odor masking and neutralizing agents
7. Use of gas-phase turbulence inducing structures and facilities
8. Establishment of buffer zones
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Odor – Treatment Methods
Fig 19.1: Odor – Treatment Methods
Typical Odor containment facilities at ETP
1. covered primary sedimentation tank
2. Covered Trickling Filter
3. Covered Sludge tank
4. Sand bed - sludge
5. Sludge removal facility
Physical Methods Chemical Methods Biological Methods
Adsorption on activated carbon
Adsorption on Sand, Soil or compost bed
Dilution with odor – free air
Masking Agent
Oxygen Injection
Scrubbing Tower
Turbulence Inducing Facilities
Odor Treatment Methods
Chemical Oxidation
Chemical Precipitation
Neutralizing Agent
Scrubbing with various alkalies
Thermal Oxidation
Activated sludge aeration tanks
Bio trickling filter
Compost filters
Sand and soil filters
Trickling filter
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Green Circle, Inc. Annexure XX 1
Annexure XX
Energy Efficient measures
• Total street lighting load-25.6 KW Out of which 2.5 KW is replenished through Solar panels
• Hot water for canteen will be provided through solar water heaters • Furnace & chiller will be run through Variable Frequency Drive(VFD) • Energy efficient compressor will be installed • Energy efficient & Eco friendly lighting fixtures in office Building. • Energy efficient Bus Bar system for plant power distribution
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Annexure XXI
Checklist in the form of Do’s & Don’ts
Do’s for Preventive maintenance
Do follow SOP for all the operations.
Do ensure that methods of access for work at height have been
properly assessed, and the safest method reasonably practicable has
been chosen
Do ensure that all materials are secure before lifting/craning above a
safety net
Do ensure that a handover certificate is completed prior to allowing
works above a safety net
DO provide and use proper rubbish bins, preferably those made of
non-combustible material like metal.
DO dispose of unwanted items at regular intervals to ensure good
housekeeping at your workplace.
DO keep corridors, walkways and passageways free of obstructions.
DO discuss project and procedures with station manager/operator
before performing service on dispenser.
DO follow lockout/tag out procedures.
DO position service vehicle to protect work area; use safety cones and
barricades to isolate your work area.
DO wear appropriate safety attire, including brightly colored vests
made of cotton, goggles and gloves.
DO properly dispose of absorbent materials and filters in an approved
container.
DO watch for sharp edges.
DO remove both doors and store in a safe place when working on
hydraulic components to ensure that the vapors can escape from
dispenser cabinet. Evacuate vapors from immediate work area if
necessary.
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DO close impact valve when working on hydraulic components.
DO use antistatic grounding techniques when servicing electronic
dispensing equipment.
DO follow manufacturer’s service and trouble shooting guidelines.
DO reopen impact valve when work is complete.
DO wear proper safety equipment.
DO know where you can get first aid.
DO keep your job site uncluttered.
DO communicate with others about safety on job site.
DO look over your job site for hazards.
DO maintain your tools for safety and effectiveness.
DO wear your seat belt at all times.
DO report all unsafe conditions to your supervisor immediately.
DO review MSDS sheets before using hazardous materials.
DO barricade work site.
DO use appropriate covers and/or barricades over open holes and
trenches.
DO be aware of what is going on around you.
DO obey all speed limits and traffic laws.
Do inspect and clean machinery and tools regularly.
Don’ts for Preventive maintenance:
DON’T assume station manager/operator knows what you are doing.
DON’T smoke around dispenser.
DON’T wear jewelry or loose clothing while servicing electrical
components and moving parts.
DON’T perform service work on a remote dispensing pump while
dispensers of the same product are operating unless the impact valve
is closed and/or electrical power to the entire system is shut down.
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DON’T use electric/spark producing tools when vapors could be
present.
DON’T allow a unit to be placed back into operation with a
“temporary fix.” Repair the unit completely.
DON’T use plastic containers to transport fuel between dispenser and
tank.
DON’T leave fuel in the sumps.
DON’T tolerate horseplay at any job site.
DON’T operate equipment under the influence of controlled
substances.
DON’T attempt to use power tools before receiving proper training.
DON’T allow safety devices to remain inoperative or in disrepair.
DON’T wear loose clothing or jewelry that could get caught in
machinery.
DON’T use substances from unmarked containers.
DON’T allow visitors to enter your work area without taking the same
safety precautions as workers.
DON’T leave open holes or trenches unattended.
DO NOT use cardboard boxes, wooden crates or other receptacles
that are made of combustible material as makeshift rubbish bins at
your workplace.
DO NOT accumulate unwanted items at your workplace.
DO NOT use corridors, walkways, or passageways that form parts of the
emergency escape route at your workplace for storage.
DO NOT accumulate unwanted items at your workplace.
DO NOT use corridors, walkways, or passageways that form parts of the
emergency escape route at your workplace for storage.
DO NOT paint over smoke / heat detectors and sprinkler heads or
hang objects on them.
DO NOT smoke in "No Smoking" areas.
DO NOT leave heavy machinery operating or running unattended.
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DO NOT leave electrical appliances or equipment continued to be
energized when they are not in use, especially after office / working
hours.
DO NOT put any liquid or thing that is flammable or combustible near
an electrical switchboard or an enclosure containing electrical
components.
Do’s & don’ts for Strengthening HSE:
DO’s: Do aware the employees about the HSE policy.
Do keep HSE manual or some instruction book let available for all
employees.
Do follow work permit system.
Do keep permit-to-work system fully documented.
Do specify the jobs & authorized person in the work permit system.
Do make staff and contractors fully understand the importance of the
permit-to-work system and trained.
Do fill inspection check list regularly.
Do keep floors clean and clear of waste.
Do prepare SOP for all the processes & operations.
Do follow the SOP for each operation.
Do keep available MSDS for all chemicals.
Do all storage areas clearly marked.
All combustible and flammable material must be present only in the
quantities needed for the job and kept in safety cans during use. Oily
or greasy rags should be placed in a metal container and disposed of
regularly.
Do keep workplaces adequately lighted.
Do keep light fixtures clean.
All the areas to be clearly marked with signage.
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DO wear proper personal protective equipment, including safety
glasses, safety shoes with slip-resistant soles, a bump cap for your head,
gloves where there is hot or sharp material, ear protection for noise,
and respiratory protection for hazardous dusts, mists, vapors or fumes.
Do ensure that the PPE is used for which it is designed.
Do give proper training to all employees for HSE awareness.
Do celebrate the programs like Safety day, Environment day to bring
the awareness among the employees.
Do carry out the cultural programs to motivate the workers.
Do report all the unsafe accidents & Incidents to the HSE dept.
Don’ts for strengthening HSE: Don’t misuse the Personal Protective Equipments.
Don’t allow the workers without PPE for the Hazardous processes.
Don’t store waste in hallways or in other public areas
Don’t use aisles and stairways as storage areas.
Don’t allow materials to build up on floors.
Don’t block emergency exits, fire equipment or first aid stations with
stored materials.
Don’t store compressed gases near heat sources.
Don’t use aisles and stairways as storage areas.
Don’t allow materials to build up on floors.
Don’t block emergency exits, fire equipment or first aid stations with
stored materials.
Don’t store the PPE at isolated place.
Don’t keep the PPE box lock.
Don’t allow the unauthorized person near machinery.
Don’t allow unauthorized entry near hazardous processes.
Don’t break the rules of HSE system.
Don’t ignore the near miss or unsafe actions or unsafe conditions.
FOR MANUFACTURING & UTILITY:
M/s. Godrej & Boyce Mfg. Co. Ltd. (PED) TOR compliance for Proposed Engineering unit along with Jetty in CRZ
area at SEZ – Dahej
Report No: GCI/V/Godrej/TOR Compliance/2010-11/May/EMS-008/R00
Green Circle, Inc. Annexure XXI 6
DO mark underground electric lines.
DO turn power off while working on electrical wiring.
DO ensure breakers are off before servicing.
DO have your tester and its attachments checked regularly.
DO test the circuit with a voltage tester before beginning work.
DO lockout the breaker for the system being used.
DO lockout/tag out the circuit.
DO follow manufacturer’s trouble shooting recommendations.
DO maintain tools in good condition.
DO be aware of vapors and other hazardous conditions.
DO know the associated hazardous location classifications.
DO use the proper fire extinguisher in case of electrical fire.
DO use the correct size wire for the run length and service
requirements.
DO verify that all work meets applicable electrical codes.
DO ensure all equipment is properly grounded.
DO verify that seal-offs are properly installed and poured.
DO assume all wiring is “hot.”
DO place barricades and caution tape around work area.
DO check jobs periodically that have been postponed to ensure
that barricades are still on site and erected.
DO escort visitors around job site.
DO post signs detailing dangers present, such as gasoline vapors,
flammable liquids, excavation work, etc.
DO have visitors leave site when vapor freeing tanks or when
hazardous conditions exist.
DO use fencing or other barriers to form a safe walk-through
corridor when performing construction work at an operating facility.
DO review scope of work, “as-built drawings,” safety concerns and
visitor control with customer.
Make sure personal protective equipment is required.
DO keep a log of visitors.
M/s. Godrej & Boyce Mfg. Co. Ltd. (PED) TOR compliance for Proposed Engineering unit along with Jetty in CRZ
area at SEZ – Dahej
Report No: GCI/V/Godrej/TOR Compliance/2010-11/May/EMS-008/R00
Green Circle, Inc. Annexure XXI 7
DO communicate safety and coordinate work with subcontractors.
DO use barricade fence and lights to identify hazardous areas.
DO assign a person to secure the site and check regulatory
compliance.
DO use ‘Danger’ — ‘Do not enter’ signs around the work area.
DO advise the site manager to warn employees about the dangers
of entering work area.
DO park visitors’ vehicles away from excavation and operating
machinery.
DO designate a smoking area, if necessary.
DO train all employees on the correct use of fire extinguishers.
DO check and maintain extinguishers properly.
DO post the telephone number of your local fire department and
burn center.
DO have regular fire drills for all personnel.
DO post fire exits and escape routes.
DO check location of fire extinguishers and fire exits when arriving
on a new job site.
DO know and review proper first aid for fire accidents.
DO ensure the detectors and sprinkler heads are not painted over
or obstructed with objects.
DO store flammable liquids in proper, unbreakable containers and
keep flammable substances in well-ventilated places and away
from any ignition source.
DO ensure ventilation openings are not sealed up and have
defective ventilation fan repaired quickly.
DO make available battery operated portable torches as a back
up.
DO observe "No Smoking" rule strictly in your premises.
DO have the equipment / machinery cleaned and serviced
regularly.
M/s. Godrej & Boyce Mfg. Co. Ltd. (PED) TOR compliance for Proposed Engineering unit along with Jetty in CRZ
area at SEZ – Dahej
Report No: GCI/V/Godrej/TOR Compliance/2010-11/May/EMS-008/R00
Green Circle, Inc. Annexure XXI 8
DO ensure that machines that are in use are tended at all times by
qualified operators
DO switch off at the mains all electrical appliances or equipment
that are not in use, especially after office / working hours.
DO ensure that the electrical switchboards and the enclosures of
electrical components are kept clear of flammable or combustible
substances and liquids.
DO dispose of oil-soaked rags in self-closing metal bins.
DO ensure the wiring is in good condition and for any defect, get a
licensed electrician to check and rectify it immediately.
DO engage licensed electricians for all electrical fitting works.
DO keep staircases free of obstructions at all times.
DO ensure fire doors are kept closed but unlocked at all times.
DO keep the hose reel cabinets and fire extinguishers free from any
obstruction.
DON’TS
DON’T work on any equipment or components unless the power is off.
DON’T assume anything.
DON’T rely on others to ensure the power is off. Check it yourself.
DON’T trust anyone else.
DON’T let wires hang.
DON’T use metal ladders near the electrical source.
DON’T use non-insulated tools for cutting wire.
DON’T lift tools by the electrical cord.
DON’T pull too many wires through a conduit.
DON’T turn the power on until work is completed and the area is safe.
DON’T assume visitors are aware of hazards at job site.
DON’T allow unauthorized visitors in the area.
DON’T allow visitors into barricaded areas unless they are essential to
the work being performed.
M/s. Godrej & Boyce Mfg. Co. Ltd. (PED) TOR compliance for Proposed Engineering unit along with Jetty in CRZ
area at SEZ – Dahej
Report No: GCI/V/Godrej/TOR Compliance/2010-11/May/EMS-008/R00
Green Circle, Inc. Annexure XXI 9
DON’T allow visitors to be near moving machinery, or operate any
equipment on site.
DON’T allow smoking or flame- or spark producing devices in
hazardous work areas.
DON’T depart job site without first making sure the site is secure.
DON’T continue to work when unauthorized visitors have entered the
area.
DON’T start work until area is secure and the owner has been advised
of the work plan.
DON’T allow visitors to enter work area without safety equipments.
DON’T allow subcontractors to enter site without proper safety training.
DON’T allow children to play around dirt piles or excavations.
DON’T leave visitors unattended.
DON’T leave site open and unmanned.
DON’T return an extinguisher after use without recharging it.
DON’T leave trash or flammable materials in workplace.
DON’T smoke in any potentially hazardous area.
DON’T store combustible materials near an open flame or heat.
DON’T obstruct path to a fire extinguisher or hydrant.
M/s. Godrej & Boyce Mfg. Co. Ltd. (PED) TOR compliance for Proposed Engineering unit along with Jetty in CRZ area
at SEZ – Dahej
Report No: GCI/V/Godrej/TOR Compliance/2010-11/May/EMS-008/R00
Green Circle, Inc. Annexure XXII 1
Annexure XXII
Traffic Survey
The traffic survey, to ascertain the traffic density in the study area was
conducted on the four lane road from Dahej to Jageshwar. The hourly counts
were carried out for the different type/category of vehicles. The variations in the
traffic flow at all the places along the number of vehicles are presented in the
following table.
UP Direction – From Dahej to Jageshwar
DOWN Direction – From Jageshwar to Dahej
Table 22.1: Traffic Survey
UP Direction DOWN Direction
SL.
No. Vehicle Type
During Lean
Hrs
(Nos./hr)
During Peak
Hrs
(Nos./hr)
During
Lean Hrs
(Nos./hr)
During Peak
Hrs
(Nos./hr)
1. Two Wheelers 12 25 10 19
2. Three Wheelers 18 22 22 31
3. Cars 4 15 5 12
4. Buses/Mini Buses 1 3 1 2
5. Trucks/ Lorries 28 36 14 41
6. Heavy vehicles 21 27 27 31
7. Slow moving vehicles 15 22 18 26
TOTAL 99 150 97 162
Note: PCU’s as per IRC-106:1990
Peak Hrs: After 8 hrs & 5 to 9 hrs in the evening
Lean Hrs: Before 8 hrs & After 9 hrs in the evening (also afternoon hrs 1 to 5 hrs)
M/s. Godrej & Boyce Mfg. Co. Ltd. (PED) TOR compliance for Proposed Engineering unit along with Jetty in CRZ area
at SEZ – Dahej
Report No: GCI/V/Godrej/TOR Compliance/2010-11/May/EMS-008/R00
Green Circle, Inc. Annexure XXII 2
Fig 22.1: Trafic Flow – Dahej to Jageshwar
Traffic flow chart : Jageshwar to Dahej
Traffic Flow - Dahej to Jageshwar
05
10152025303540
Lean Hrs Peak Hrs
Vehi
cles
/Hr.
Two Wheelers Three Wheelers CarsBuses/Mini Buses Trucks/ Lorries Heavy vehicles
Slow moving vehicles
M/s. Godrej & Boyce Mfg. Co. Ltd. (PED) TOR compliance for Proposed Engineering unit along with Jetty in CRZ area
at SEZ – Dahej
Report No: GCI/V/Godrej/TOR Compliance/2010-11/May/EMS-008/R00
Green Circle, Inc. Annexure XXII 3
Table 22.2: Traffic Survey
UP Direction DOWN Direction
SL.
No. Vehicle Type
No. of
Vehicles in
PCU’s -
Lean Hrs
No. of
Vehicles in
PCU’s -
Peak Hrs
No. of
Vehicles
in PCU’s -
Lean Hrs
No. of
Vehicles in
PCU’s - Peak
Hrs
1. Two Wheelers 9 19 8 9
2. Three Wheelers 36 44 44 62
3. Cars 4 15 5 12
4. Buses/Mini Buses 7 7 2 4
5. Trucks/ Lorries 104 133 114 152
6. Heavy vehicles 105 135 135 155
7. Slow moving vehicles 8 11 9 13
TOTAL 273 364 317 407
M/s. Godrej & Boyce Mfg. Co. Ltd. (PED) TOR compliance for Proposed Engineering unit along with Jetty in CRZ area
at SEZ – Dahej
Report No: GCI/V/Godrej/TOR Compliance/2010-11/May/EMS-008/R00
Green Circle, Inc. Annexure XXII 4
Existing Traffic Scenario & Level of Services
All types of vehicles move on the road. As per IRC, subject road is a four lane
road of capacity 4000 PCU’s/hr.
Up Direction
Total Volume during Peak Hours = 364
Existing Volume/Capacity ratio = 364 / 4000 = 0.09
The level of service is “A” that is Excellent.
Down Direction
Total Volume during Peak Hours = 407
Existing Volume/Capacity ratio = 407 / 4000 = 0.10
The level of service is “A” that is Excellent.
Level of Service:
Table 22.3: Level of Service
SL.
No.
Existing
Volume/Capacity
Ratio
Level of Services
1 0.0 to 0.2 “A” (Excellent)
2 0.2 to 0.4 “B”(Very Good)
3 0.4 to 0.6 “C” (Good)
4 0.6 to 0.8 “D” (Fair)
5 0.8 to 1.0 “E” (Poor)
M/s. Godrej & Boyce Mfg. Co. Ltd. (PED) TOR compliance for Proposed Engineering unit along with Jetty in CRZ area
at SEZ – Dahej
Report No: GCI/V/Godrej/TOR Compliance/2010-11/May/EMS-008/R00
Green Circle, Inc. Annexure XXII 5
Modified Traffic Scenario & LOS (After completion of the project):
367 vehicles (in PCU’s) assume to enter during 3 hrs and exit during 3 hrs
Additional volume in PCU’s/hr will be 367/3 = 122 PCU’s/hr during peak hours.
Up Direction
Total volume during peak hours (V) = 364 + 122 = 486
Modified Existing Volume/Capacity ratio (V/C) = 486/4000 = 0.123
The level of service will be “B” that is Very Good after construction.
Down Direction
Total volume during peak hours (V) = 407 + 122 = 529
Modified Existing Volume/Capacity ratio (V/C) = 529/4000 = 0.132
The level of service will be “A” that is Excellent after construction.
Parking Statement
Table 22.4: Parking Statement
No. Type of Vehicles No. of Parking required No. of Parking
Provided
1 Two wheeler 296 296
2 Car 94 94
3 Truck 23 23
M/s. Godrej & Boyce Mfg. Co. Ltd. (PED) TOR compliance for Proposed Engineering unit along with Jetty in CRZ
area at SEZ – Dahej
Report No: GCI/V/Godrej/TOR Compliance/2010-11/May/EMS-008/R00
Green Circle, Inc. Annexure XXIII 1
Annexure XXIII
The main building materials used for the project are cement, aggregates, steel,
fly ash blocks, aluminum, glass, iron and china mosaic. These materials are
manufactured integrating the recycled component to the allowable extent as
mentioned here below:
• Steel : 20-25%
• Cement : 25-30%
• Fly-ash Blocks : 30-40%
• Glass : 10-15%
• Ceramic tiles : 20-30%
• MDF Wood : 15%
• Roofing Tiles : 25-30%
Copper slag (70%) and Fly-ash (30%) mix will be used as the filling material for
the road and flooring works.
Apart from the materials mentioned above other preferred materials to be used
within the scope of this project shall have recycled content. The prospective
users of the area will be emphasized to integrate recycle materials in their interior
design.
___________________________________________________________________________ M/S Godrej & Boyce Page 1 of 5 May-10
FIRE PROTECTION SYSTEM FOR M/S GODREJ & BOYCE MANUFACTURING CO.LTD.
DAHEJ-GUJARAT
DESIGN PHILOSOPHY FOR FIRE PROTECTION SYSTEM
INDEX
1 INTRODUCTION………………………………………………………2
1.1 Codes and Standards………………………………………………………2 1.2 Protection against Freezing……………………………………………… .2 1.3 Design Conditions ………………………………………………………….2
2 HAZARD CLASSIFICATION …………………………………………………...3
2.1 Total Hydrant Load……………… ………………………………………....3 2.2 Hazard and Pumping Requirement as per Standards ………………….3 2.3 Reservoir …………………………………………………………………….3
3 BASIC SYSTEMS DESIGN & OPERATION ……………………………………4
3.1 External Fire Hydrant System………………………………………………4 3.2 Hydrant system Operation ………………………………………………….4
3.3 Sprinkler System Operation ………………………………………………..4 3.4 Fire Extinguisher …………………………………………………………….4
3.4.1 Reference Standards …………………………………………………...5 3.4.2 System Description ……………………………………………………..5
DESIGN PHILOSOPHY ___________________________________________________________________________
___________________________________________________________________________ M/S Godrej & Boyce Page 2 of 5 May-10
1 INTRODUCTION This specification covers the design basis and the design requirements of fire fighting system for M/S GODREJ & BOYCE MANUFACTURING CO.LTD. DAHEJ-GUJARAT (referred to as “Plant” hereafter). The term, Fire Fighting System, used in this specification are measures to be taken to minimize, control and extinguish fires already burning, for the purpose of life safety and properly protection. The fire fighting system is provided for the purpose of fire extinguishing, fire intensity control, and /or fire exposure protection. The fire protection system is being designed to meet the largest fire water demand in the plant. The system is proposed to have common above ground pressurized mains for sprinkler and hydrant system.
Codes and Standards Local and government requirements and international regulation like NBC-2005 and corresponding IS codes shall be applied for the fire fighting system. Equipment, material and devices used for the fire fighting system shall be designed, manufactured, tested and inspected in accordance with the requirements of Indian Standards (IS) for Indian manufacture’s practice may be applied for design and manufacturing of equipment unless specified in the codes or standards of manufacturing country, this specification or IS/NFPA. The Specifications shall comply with following standards : National Building Code – 2005 Indian Standards (IS) – 3844 – Fire Fighting system Indian Standards (IS) – 2190 – Portable Fire Extinguishers Indian Standards (IS) – 15105- IS Standard for Sprinkler Systems 1.2 Protection against Freezing The firewater piping shall be designed for non-freezing condition as there are no freezing conditions at site. 1.3 Design Condition Design Pressure Design pressure of the equipment and materials used in the fire water network and the water fire fighting system shall not be less than the sum of maximum suction pressure and shut off pressure of the fire water pump. Design temperature The design temperature for the equipment and material shall be; 55 oC for those subject to direct sun 45 oC for those not subject to direct sun 2.1.1 Total Hydrant Load
Table 1.
Description Qty Equivalent hydrants
Single hydrant SH 31 31 Fire Escape Hydrants FEH 02 02 Monitor WM 02 06 Total Load 39
DESIGN PHILOSOPHY ___________________________________________________________________________
___________________________________________________________________________ M/S Godrej & Boyce Page 3 of 5 May-10
Legend: SH - Single Headed Hydrant WM - Water Monitor 2.2 Hazard and Pumping Requirement as per Standards SPRINKLER SYSTEM: For Admin Area only and any other Future expansion area.
As per NBC/IS CLAUSE Hazard Hazard Moderate Table 23 Storage Capacity
Storage Capacity
NR Table 23 (Clauses 4.18.2,6.1.2,6.2.3,6.3.2,6.4.3,6.5.2,6.5.2.1,6.5.2.2,6.5.2.3,6.5.2.4,6.5.2.5,6.6.2,6.7.2,6.7.2,6.8.2 and 6.9.2)
Pump Capacity Pump Capacity
137 m3/hr @ 70 MWC
All Above and as per note 20
HYDRANT SYSTEM: Coutryard along the perimeter.
As per NBC/IS Hazard Hazard Low Storage Capacity Storage
Capacity 100000 Liters Table 1 (Clauses
4.1.1,4.1.2,5.1.1,5.2.1 ,5.3.1,5.4.1 AND 7.2) Pump Capacity Pump
Capacity 137 m3/hr @ 70 MWC
The fire water pump system shall be provided for the plant as follows: Pumping Capacity for Hydrant : 137 Cubic Mtr @ 70 MWC Pumping Capacity for Sprinkler : 137 Cubic Mtr @ 70 MWC Standby Diesel Engine Pump : 137 Cubic Mtr @ 70 MWC Common Jockey Pump set : 10.8 Cubic Mtr @ 70 MWC Tapping for Spray System for LPG Bullets shall be provided from Hydrant Ring Main. Design of Spray system is not part of this scope. 2.3 Reservoir 2.3.1 Fire Water Source Raw water shall be used as fire water. Fire water shall be stored in the two Fire water tanks with a minimum effective storage capacity of 100 m3 in 2 compartments. 3 BASIC SYSTEMS DESIGN & OPERATION The entire plant is provided with the following type of fire protection systems.
• External Fire Hydrant system • Internal Hose Reel Connection • Pumping system • Fire extinguishers
DESIGN PHILOSOPHY ___________________________________________________________________________
___________________________________________________________________________ M/S Godrej & Boyce Page 4 of 5 May-10
3.1 External Fire Hydrant System The hydrants are spaced as per Light hazard at 45 m spacing. The entire plant is being protected with hydrants and the distribution of the hydrants is as per Table 1. The quantity of hydrants is tentative and the exact quantity shall be worked out during details engineering by the fire fighting vendor as per NBC/IS guidelines. The vetting of the entire fire fighting system from NBC/IS (Local CFO) accredited professional agency and getting approval shall be the responsibility of the fire fighting vendor. The hydrant system is designed to protect the buildings and equipments by providing hydrants around the area as mentioned above. The system mains run above ground and shall be provided with required number of tees with blind flanged joints to facilitate future expansion. The installation is to provide with adequate number of isolation valves at suitable locations for the purpose of isolation during the event of fire or during emergencies. 3.2 Hydrant system Operation Maximum operating pressure required at the remotest point as per NBC/IS – 3.5 kg/cm2 All above pump sets are to be installed in the Fire Water pump house. The fire water pump system shall be operated as follows: The jockey pumps shall be activated/ de-activated through a pressure switch mounted on the pumps discharge header so as to maintain the network pressure around 7.0 kg/cm2. At normal static condition of the network, the charged pressure of 7.0kg/cm2 shall be maintained. When pressure falls below 7.0 kg/ cm2 due to minor leakage any where in the network and it reaches to 6.0 kg/ cm2g, the jockey pump automatically will come in to operation and thus maintains the network pressure of 7.0 kg/ cm2 and stops automatically. Jockey pumps shall be inter-linked with main pumps, so that in the event of starting of main pump, jockey pump shall stop automatically, if jockey pump is running. In the event of more fire water demand at required pressure the jockey pump can not fulfill, the main electric pumps fire water pumps shall kick-in automatically in sequence at 5.0 kg/ cm2 and incase Electric pump fails to start and the pressure drops below 4.0 kg/cm2 the Diesel Engine starts automatically. The fire water pump suction shall be sized such that with pump operating at 150% of rated capacity, the velocity in the suction pipe does not exceed 4.50 m/s. All pumps shall be preferably centrifugal type pumps. The fire water pumps shall have relatively flat characteristic curves furnishing not less than 150% of the rated capacity at not less than 65% of rated head. The fire water pump shut-off head shall not exceed 120% of the rated head. 3.3 Sprinkler System Operation Maximum operating pressure required at the remotest point as per NBC/IS – 0.5 kg/cm2 A sprinkler has two functions to perform. It must first detect a fire and must then provide an adequate distribution of water to control / extinguish it. The classic use of the sprinkler is in the hot gas layer which forms beneath the ceiling of an enclosure in which a fire is developing. The sprinkler operate at pre-determined temperatures to discharge water over the affected part of the area below, the flow of water through the alarm valve initiating a fire alarm. The operating temperature is generally selected to suit ambient temperature conditions. only sprinkler in the vicinity of the fire.i.e those which become sufficiently heated operated. The hydrant mains are hydraulically designed & checked so that when maximum sprinklers demand is discharged at one end and simultaneously the assumed hose stream is discharged at the other farthest / hydraulically remote point in the most vulnerable area reroute, a minimum pressure of 5.2 kg/cm2 is available at the former points and the velocity is generally restricted to 4.5 m/sec and in any case does exceed 5m/sec. The sprinkler system is considered in Warehouse area only.
DESIGN PHILOSOPHY ___________________________________________________________________________
___________________________________________________________________________ M/S Godrej & Boyce Page 5 of 5 May-10
3.4 FIRE EXTINGUISHER Portable fire extinguisher shall be provided for the Plant as a first aid safety measure. The objective is to protect the entire premises with suitable Fire Extinguishers approved and certified for particular application. The extinguishers shall form as a first aid action against small and incipient fire so as to extinguishing of the fire even before it develops into a major hazard. 3.3.1. REFERENCE STANDARD The requirement of the extinguishers shall meet the IS 2190 guidelines. 3.3.2. SYSTEM DESCRIPTION The Extinguishers proposed is to protect the all equipments, areas with relevant type of suitable Fire Extinguishers. Carbon-di-oxide Extinguishers are proposed as it is an inert gas with no residue, is electrically non-conductive and ideal for all electronic and electric protection application. ABC type Extinguishers are proposed for Type ‘A’ class fire, which is stored, pressured type and used to protect against fires causing from tables, furniture’s, curtains etc. Water/ Foam Type Extinguishers are proposed for protect against fire causing from liquid (kitchen oil) fires caused in pantry areas. Portable fire extinguishers of water (Gas pressure) type of 9 liters capacity, Carbon-di-oxide of 4.5 kg and ABC Type 5 Kg capacity shall be provided as first aid fire extinguishing appliances. The appliances shall be so distributed over the entire floor area so that a person has to travel not more than 25 m to reach the nearest appliance. These shall be placed or hanged on wall in a group on several suitable places. The number of extinguishers shall be calculated as per IS 2190 ------------------------------------ END OF DOCUMENT ------------------------------
M/s. Godrej & Boyce Mfg. Co. Ltd. (PED) TOR compliance for Proposed Engineering unit along with Jetty in CRZ
area at SEZ – Dahej
Report No: GCI/V/Godrej/TOR Compliance/2010-11/May/EMS-008/R00
Green Circle, Inc. Annexure XXV
Annexure XXV
Details of the debris management plan along with the use/disposal of
excavated soil during construction phase and top soil conservation plan.
• Proper barricading and enclosures (minimum 20 ft) will be provided at
the construction site to avoid escape of fugitive dust into atmosphere
as well as its deposition and spreading on streets / footpaths / drains
etc.
• Debris / construction waste generated will be stored in proper
container before it is transported.
• Debris or other construction material required during the construction
will be stored within working area and not on the roads.
• The vehicles deployed shall be properly covered with tarpaulin or other
suitable materials firmly fixed on the vehicles to ensure that neither any
dust escapes nor any debris is allowed to fall on the roads during
transportation.
• It will be ensured that arrangements to clean / wash vehicles carting
dust / debris before they move on the streets. Water will be sprinkled
on the earth filled vehicles to prevent dust while transporting.
• Noise levels during construction will be restricted within permissible
limits.
• The excavated earth, debris, construction waste generated will be
absorbed with in the site or transported to places within our own site.
• Excavated earth / debris / construction waste will not be dumped into
any dumping site.
• Surrounding vicinity of the site will be maintained aesthetically abutting
the road and utilization of debris within the site will not cause any
obstruction or stagnation.
• No building material used, unused, waste, all type of debris or its
residues will be scattered on portions of footpath / roads outside the
plot.
M/s. Godrej & Boyce Mfg. Co. Ltd. (PED) TOR compliance for Proposed Engineering unit along with Jetty in CRZ
area at SEZ – Dahej
Report No: GCI/V/Godrej/TOR Compliance/2010-11/May/EMS-008/R00
Green Circle, Inc. Annexure XXVI 1
Annexure XXVI
Details of the basic amenities and welfare facilities to be provided to the
construction workers to ensure that they do not damage the existing
environment.
• Adequate on-site sanitation facilities will be provided for the construction
laborers so as to avoid defecation in and around project site.
• Few numbers of toilets comprising latrine, bath and hand wash facilities
will be constructed in the labour camp.
• Septic tank will also be constructed for collection and treatment of
domestic wastewater generated from the construction laborers use.
• Adequate water supply for drinking and other domestic uses will also be
provided during the construction stage of the project.
• There will not be any unsanitary conditions created around the project site
due to deployment of construction labour during the construction stage
of the project.
M/s. Godrej & Boyce Mfg. Co. Ltd. (PED) TOR compliance for Proposed Engineering unit along with Jetty in CRZ
area at SEZ – Dahej
Report No: GCI/V/Godrej/TOR Compliance/2010-11/May/EMS-008/R00
Green Circle, Inc. Annexure XXVIII 1
Annexure XXVIII
Details of Corporate Social Responsibilities.
• We are planning to create residential, medical, educational and
recreational facilities for our employees.
• We have already contributed Rs. 12, 00, 000/- to PCPIR Welfare Society for
rehabilitation of affected villagers due to SEZ and an equal amount to
Dahej SEZ Limited towards the cess amount for the welfare of Construction
Workers and their family members.
• We will be contributing for relocation of temple situated in our plot Z-90 at
SEZ Dahej.
• For larger community we will be having Rural Development Programmes
for upliftment of people in the form of de-addiction, self-help, vocational
training and guidance etc.
Ref, NO: PEWPROJfEc104 m: 11mm10
The Secretary, State ~eve-4 €qmi Apprakul Cclrnrnltbe- Wjgrcd. Fomt & E n v k ~ n t Departmmt. B W no. 1 4/8, Sachiv~~ya,
-383 010 -- &&: mvitomntat Ciearawe for p r m ptqect To devebp an -€ngitw&ng m# W FaMcafkm of Procesf Ecp@mm% dm.8 with Jew h CRZ area at Pkrt no. E-90. SEf - Dahej, V i w - LWCBTQ, Tdvka V-, DlstrScl - EUl-h, GujaC~?. - - mg TOR potnts f ~ e b & frm SfAC wfth Ref. NO- : BA -10-200P-567-E dated 226 Wuw. 2010
lhis is in r g f e r w of TOR pol& mcePIed SEAC dated r2"6 Feb, 2010 that t%bEc comdWon process 3s mqWed formid P@ect.
Wh&easC a5 per the Mhbw of Envkorwrrenf and Fwests, Mew Dew -.8A Nofrficdon Med li 4@ September. 2006. ttw Proposed Project site is a pc#t of EtDf: md x, Pubdie c o m n process k not required as pes 7[if stage I fb) On P a g e nM.
Kbd& msiderfbe same for above said prujw3 Qakd exempt us &am public hearing.
%Godre] L byce.MlgSo. Lid