Final EIA report for Proposed Technical Manufacturing Plant at DLCT- 1, Domestic Tariff Area, Gopalpur Industrial Park, Chamakhandi, Tehsil- Chatrapur, District- Ganjam, Odisha-761020 by M/s Smartchem Technologies Ltd. (STL)

CHAPTER 7. ADDITIONAL STUDIES

This Chapter provides the details about the Quantitative Risk Assessment and emergency plan as proposed for the proposed project.

7.1. Introduction Industrial plants deal with materials, which are generally hazardous in nature by virtue of their intrinsic chemical properties or their operating temperatures or pressures or a combination of these. Fire, , toxic release or combinations of these are the hazards associated with industrial plants using hazardous chemicals. More comprehensive, systematic and sophisticated methods of Safety Engineering, such as, Hazard Analysis and Quantitative Risk Assessment have now been developed to improve upon the integrity, reliability and safety of industrial plants.

The primary emphasis in safety engineering is to reduce risk to human life, property and environment. Some of the more important methods used to achieve this are

• Quantitative Risk Analysis: Provides a relative measure of the likelihood and severity of various possible hazardous events by critically examining the plant process and design.

• Work Safety Analysis: The technique discerns whether the plant layout and operating procedures in practice have any inherent infirmities.

• Safety Audit: Takes a careful look at plant operating conditions, work practices and work environments to detect unsafe conditions

Together, these three broad tools attempt to minimize the chances of accidents occurring. Yet, there always exists, no matter how remote, probability of occurrence of a major accident. If the accident involves highly hazardous chemicals in sufficiently large quantities, the consequences may be serious to the plant, to surrounding areas and the populations residing therein.

7.2. Scope of Work The scope of the study is to model and appraise the risks associated with all toxic , flammable and explosive hazards resulting from potential loss of containment accident scenarios from M/s Smartchem Technologies Limited (henceforth STL) Operations of Technical Ammonium Nitrate Plant [which comprises of 900 MTPD (100% basis) Nitric Acid (NA) plant to manufacture Ammonium Nitrate solution 1143 MTPD (100% basis] at the Industrial Park being developed by Tata Steel SEZ Limited (TSSEZL) at Gopalpur, Odisha and developing a Disaster Management Plan.

7.3. Objectives The specific objectives of the study are to identify:

• Hazardous materials associated with the project

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• Potential consequences of identified threats • Recommend risk prevention and reduction measures to ensure that all risks are within ALARP. • Defines the actions to be taken in case of emergencies.

7.4. Methodology of HIRA Hazard Identification and Risk Assessment:

Hazard is defined as a chemical or physical condition those have the potential for causing damage to people, property or the environment. In this chapter the hazards associated with only the proposed expansion project have been discussed.

The primary step of the Hazard identification is the risk analysis and entails the process of collecting information on:

• the types and quantities of hazardous substances stored and handled at the plant, • the location of storage tanks & other facilities, and • potential hazards associated with the spillage and release of hazardous chemicals.

7.4.1. Identification of Hazards

The main hazard potentials in the proposed Plant, Plant are categorized as below: • Material hazards; Associated with Hazardous Materials Storage Facilities. • Process hazards due to loss of containment during handling of hazardous materials or processes resulting in fire, explosion, etc • Mechanical hazards due to "mechanical" operations such as welding, maintenance, falling objects etc. - basically those NOT connected to hazardous materials. • Electrical hazards: electrocution, high voltage levels, short circuit, etc. Out of these, the material and process hazards are the one with a much wider damage potential as compared to the mechanical and electrical hazards, which are by and large limited to very small local pockets.

7.5. Hazardous Materials Bulk Storages at STL Plant The major hazardous chemical to be stored at the STL site will be Ammonia, Ammonium Nitrate, Chlorine, fuel and other hazardous chemicals etc. as given below in the Table 7.1: Table 7.1 : Bulk Storages at STL Plant Sr No. Hazardous Chemical Type of storage Capacity in MT Ammonia Atmospheric 1. Ammonia 10,000 X2 Storage Tanks Overall TAN storage 2. Ammonium Nitrate (TAN) 4400 capacity Weak Nitric acid 3. Tank 1500 X 4 (100 % Basis)

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Ammonium nitrate 4. solution storage (100 % Tank 3 x 30 Basis) 5. Sulphuric Acid (98%) Tank 25 X 1

6. Caustic (48-50%) Tank 35 X 1

7. Coal for Boiler Bulk 2000

8. Chlorine 100 kg cylinders 5 cylinders

9. Diesel Tank 990 litres

10. LPG 19.5 kg cylinders 5 cylinders

7.5.1. Hazardous Analysis of Bulk Storage Materials STL will be using several raw materials but only few are stored in bulk and few chemicals are listed under “List of hazardous and Toxic Chemicals” category under MSIHC Rules, 1989. The raw materials coming under hazardous category as specified by MSIHC Rules, 1989 (including subsequent amendments) is given in Table 7.2 below:

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Table 7.2 : Hazard Analysis of Bulk Storage Materials S No Material S. No & Threshold Quantity (TQ in Chemicals Hazards Potential Remarks Kg) as per MSHIC Rules Schedul Schedule- Schedule-3, Hazards Toxic e-1, 2, Part-I DT->---mg/Kg; Part-II OT----mg/Kg; IT----mg/l; (Rats) 1. 31 2 105 Fire Hazards: (Gas); Mixing ERPG-1: 25 ppm Contact with liquid may cause Ammonia TQ-1: 60 TQ-1: 50 MT of ammonia with several ERPG-2: 150 ppm froast bite. MT TQ-2: 500 chemicals can cause fire IDLH: 300 ppm TQ-2: 600 MT hazards, / or ; MT vapours are toxic- irritation to eyes and respiratory tract. 2. 423 -- -- Yellow to brown liquid with Inhalation LC-50 (rat Eye: Causes severe eye burns. Nitric Acid suffocating strong odour 4-h): 0.13 mg/L May cause irreversible eye HNO3 – 60-62%; 2 ppm TWA; 4 ppm injury.

NO2->6%’ STEL Skin: Exposure of the skin to the liquid or concentrated CAS No.: 7697- vapor produces severe and 37-2 penetrating burns. Ingestion: Causes gastrointestinal tract burns Inhalation respiratory tract. 3. 33 --- 126 Ammonium nitrate is ; d steel Ammonium TQ-1: 350 moderately toxic if large Nitrate MT amounts are swallowed; CAS No: 6484- TQ-2: 2500 Highly Reactive 52-2 MT

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S No Material S. No & Threshold Quantity (TQ in Chemicals Hazards Potential Remarks Kg) as per MSHIC Rules Schedul Schedule- Schedule-3, Hazards Toxic e-1, 2, Part-I DT->---mg/Kg; Part-II OT----mg/Kg; IT----mg/l; (Rats) White odourless When heated to prills, with decomposition (unconfined) strong ammonium nitrate produces disagreeable nitrous oxides, white acrid taste. ammonium Ammonium nitrate fumes. nitrate is not Ammonium nitrate is flammable. incompatible with copper, zinc, or their alloys (i.e., Gr. 3-Highly bronze, brass, galvanised Reactive metals, Substance etc.), aluminium powder Decomposes and mil from 170 °C before boiling 4. 119 5 108 ERPG-1: 1.0 ppm Hazards: Poisonous; may be Chlorine TQ-1: 10MT TQ-1: 10MT Non Combustible; May ERPG-2: 3.0 ppm fatal if inhaled. Contact may CAS No:7782- TQ-2: 25 TQ-2: 25 MT ignite other combustible ERPG-3: 20 ppm cause burns to skin and eyes. 50-5 MT materials (wood, paper, oil, IDLH: 10 ppm Bronchitis or chronic lung UN No:1017 etc.). Mixture with fuels may conditions cause explosion. Container Poisonous; may be fatal if may explode in heat of fire. inhaled. Contact may cause

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S No Material S. No & Threshold Quantity (TQ in Chemicals Hazards Potential Remarks Kg) as per MSHIC Rules Schedul Schedule- Schedule-3, Hazards Toxic e-1, 2, Part-I DT->---mg/Kg; Part-II OT----mg/Kg; IT----mg/l; (Rats) A greenish Chlorine reacts explosively burns to skin and eyes. yellow gas with with or supports the burning Bronchitis or chroniclung a pungent of numerous common conditions suffocating odor. Toxic by inhalation. 5. 591 Flammability: Will not burn ERPG-1: 2.0 mg/m3 Sulphuric Acid Health Hazard: Extremely CAS No: 7664- ERPG-2: 10 mg/m3 hazardous - use full 93-9 UN No: protection; Reactivity: ERPG-3: 30 mg/m3 1830 Violent chemical change IDLH: 15 mg/m3 possible 6. 571 ------Not flammable; Corrosive to ERPG-1: 0.5 ppm Caustic Soda metals and tissue. (Sodium ERPG-2: 5.0 ppm Hazardous. Hydroxide) ERPG-3: 50 ppm CAS No: 1310- 730-2 IDLH: ---- ppm UN No: 1823 7. LPG 347 6 1 Inhalation: --- Colourless / TQ-1: 50 TQ-1: 15MT • Irritation of eyes & Odourless (but MT TQ-2: 200 respiratory tract MT • Burning action on skins

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S No Material S. No & Threshold Quantity (TQ in Chemicals Hazards Potential Remarks Kg) as per MSHIC Rules Schedul Schedule- Schedule-3, Hazards Toxic e-1, 2, Part-I DT->---mg/Kg; Part-II OT----mg/Kg; IT----mg/l; (Rats) odorized to TQ-2: 300 detect leakage MT Explosive range: 4.9— 9.5%

8. Diesel --- 30 6 Entry through LD50 (oral rat)- 2800 Flammable TQ-1: TQ-1: 5000 inhalation, ingestion mg/kg; LD50 - Liquid- 15000MT MT and skin; 200;TLV(ACGIH)- 5 Class-3 TQ-2: TQ-2: 50000 Inhalation Effects: mg/kg; STEL- 10 Hazardous 100000 MT MT Dizziness and headache, mg/kg Aspiration – Rapidly developing, potential fatal chemical pneumonities Ingestion Effect: Nausea and Vomiting; Contact Effects: Irritation, Eyes- Irritation; Dermatitis may develop on prolonged contact.

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The petroleum materials (HSD and LPG) used in STL plant and their hazardous nature are as below in Table 7.3:

Table 7.3 : Petroleum Products in STL and hazardous nature Item Physical Impact on Man, Animal & Eco-System Physical Chemical LDO/HSD BP- 150 – 400°C LEL -0.6% (V/V) Entry through inhalation, ingestion and skin; UN No.-1202 Vapour Pressure UEL – 7.5% (V/V) Inhalation Effects: Dizziness and headache, Aspiration – Rapidly Flammable Liquid-Class-3 (35°C)- <1 mm at Flash Point > 32° C developing, potential fatal chemical pneumonities Hazardous Waste ID No.-17 38°C Auto ignition Ingestion Effect: Nausea and Vomiting; Hazchem Code-3Y* Specific Gravity- Temp.-256° C Contact Effects: Irritation, Eyes- Irritation; Dermatitis may develop NFPA Hazards Signals 0.81 – 0.91 at 20°C Stable compound on prolonged contact. Health-0 Solubility in water- Incompatible with LD50 (oral rat)- 2800 mg/kg; LD50 -200;TLV(ACGIH)- 5 mg/kg; STEL- Flammability-2 Insoluble oxidizing agents. 10 mg/kg Reactivity/ Stabilty-0 LPG • Irritation of eyes & respiratory tract Colourless / Odourless • Burning action on skins (but odorized to detect TLV-8 hrs: 1000 PPM leakage) Explosive Range: 4.9— 9.5%

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STL main product i.e., Ammonium Nitrate has been mentioned in MSHIC Rules (both in Schedule 1 & 3) and as such is highly hazardous (explosive). It is stored in bulk (but in limited quantity) The main raw material (Ammonia) is stored in bulk and other associated materials stored in bulk are intermediate product i.e., Nitric Acid, Chemicals i.e., Chlorine, Sulphuric acid, Caustic lye, fuels-coal, LDO, LPG etc. The solid materials (except coal) will be received in bags or drums and will be stored in chemicals godowns. The products (solid) will be packed in bags and stored in product godowns as per market demand. The bulk storages of liquid/gaseous hazardous materials are given in the Table 7.1. The solid materials powder or granules spillage can result in polluting small area only. The damage to personnel can be through ingress- dermal (if individual come in contact), oral (if individual food gets infected through fugitive dust) or inhalation (fugitive dust). The main route is fugitive dust which in covered area will move to short distance only. The risk is through liquid and gaseous materials which are volatile material. The toxic vapours/gas due to spillage/leakage of such material can travel to some distance and cause damage.

7.6. Detailed QRA Approach: Rule Sets and Assumptions Identification of hazards and likely scenarios (based on Level-1 and Level-2 activities) calls for detailed analysis of each scenario for potential of damage, impact area (may vary with weather conditions / wind direction) and safety system in place. Subsequently each incident is classified according to relative risk classifications provided in Table 7.4: Table 7.4 : Risk Classification Stage Description High A failure which could reasonably be expected to occur within the expected (> 10-2/yr.) lifetime of the plant. Examples of high failure likelihood are process leaks or single instrument or valve failures or a human error which could result in releases of hazardous materials. Moderate A failure or sequence of failures which has a low probability of occurrence (10-2 --10-4/yr.) within the expected lifetime of the plant. Examples of moderate likelihood are dual instrument or valve failures, combination of instrument failures and human errors, or single failures of small process lines or fittings. Low A failure or series of failures which have a very low probability of (<10-4) occurrence within the expected lifetime of plant. Examples of ‘low’ likelihood are multiple instruments or valve failures or multiple human errors, or single spontaneous failures of tanks or process vessels. Minor Incidents Impact limited to the local area of the event with potent for ‘knock – on- events’

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Stage Description Serious One that could cause: Incident 1. Any serious injury or fatality on/off site; 2. Property damage of $ 1 million offsite or $ 5 million onsite. Extensive One that is five or more times worse than a serious incident. Incident Assigning a relative risk to each scenario provides a means of prioritising associated risk mitigation measures and planned actions. 7.6.1. Thermal Hazards To understand the damages produced by various scenarios, it is appropriate to understand the physiological/physical effects of thermal radiation intensities. The thermal radiation due to tank fire usually results in burn on the human body. Furthermore, inanimate objects like equipment, piping, cables, etc. may also be affected and need to be evaluated for damages. Tables 7.5, 7.6 and Table 7.7 respectively give tolerable intensities of various objects and desirable escape time for thermal radiation. Thermal hazards could be from fires or explosion. Fire releases energy slowly while explosion release energy very rapidly (typically in microseconds). Explosion is rapid expansion of gases resulting in rapidly moving shock wave. Explosion can be confined (within a vessel or building) or unconfined (due to release of flammable gases). BLEVE (boiling liquid expanding vapour explosion) occurs if a vessel containing a liquid at a temperature above its atmospheric boiling point ruptures. The subsequent BLEVE is the explosive vaporisation of large fraction of its vapour contents; possibly followed by combustion or explosion of the vaporised cloud if it is combustible range. Thermal hazards have been considered for various scenarios including: Fire in fuel storage tank. Table 7.5 : Effects due to Incident Radiation Intensity Incident Radiation Damage Type kW/m2 0.7 Equivalent to Solar Radiation 1.6 No discomfort on long duration Sufficient to cause pain within 20 sec. Blistering of skin (first 4.0 degree burn are likely). Pain threshold reached after 8 sec. Second degree burn after 20 9.5 sec. Minimum energy required for piloted ignition of wood, melting of 12.5 plastic tubing etc. Minimum Energy required for piloted ignition of wood, melting, 25 plastic tubing etc. 37.5 Sufficient to cause damage to process equipment. 62.0 Spontaneous ignition of wood.

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Table 7.6 : Thermal Radiation Impact to Human Exposure Radiation Energy {1% Radiation Energy for Radiation Energy for Duration lethality; kW/m2} 2nd degree burns; 1st degree burns; kW/m2 kW/m2 10 sec 21.2 16 12.5 30 9.3 7.0 4.0

Table 7.7 : Tolerable Intensities for Various Objects Sl. No Objects Tolerable Intensities (kw/m2) 1 Drenched Tank 38 2 Special Buildings (No window, fireproof doors) 25 3 Normal Buildings 14 4 Vegetation 10-12 5 Escape Route 6 (up to 30 sec.) 6 Personnel in Emergencies 3 (up to 30 sec.) 7 Plastic Cables 2 8 Stationary Personnel 1.5

1. Damage due to Explosion The explosion of a dust or gas (either as a deflagration or detonation) results in a reaction front moving outwards from the ignition source preceded by a shock wave or pressure front. After the combustible material is consumed the reaction front terminates but the pressure wave continues its outward movement. Blast damage is based on the determination of the peak overpressure resulting from the pressure wave impacting on the object or structure. As a safety measure STL is storing highly hazardous materials in isolated places with full safety measures. Damage estimates based on overpressure are given in Table 7.8 below: Table 7.8 : Damage due to Overpressure Sl. No Overpressure (psig / Damage bar) 1. 0.04 Loud Noise / sonic boom glass failure 2. 0.15 Typical pressure for glass failure 3. 0.5 - 1 Large and small windows usually shattered 4. 0.7 Minor damage to house structure 5. 1 Partial demolition of houses, made uninhabitable. 6. 2.3 Lower limit of serious structure damage 7. 5 – 7 Nearly complete destruction of houses 8. 9 Loaded train box wagons demolished 9. 10 Probable destruction of houses 10. 200 Limits of crater lip

In STL case explosion possibility is there mainly due to Ammonium Nitrate.

7.6.2. Toxic Release Hazardous materials handled and stored in bulk in STL complex are toxic gas (chlorine)/ chemicals (as detailed in Table 7.1) and other raw materials as defined in MSHIC rules and

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indicated in Table 7.2. Some of these chemicals are stored in bulk (in Godown (Ammonium Nitrate)/ tank farm). Damage criteria: For toxic release the damage criteria considered is IDLH concentration (if data are available). In the absence of non-availability of IDLH, ‘Inhalation Toxicity (IT) data for rats’ are considered.

7.7. Associated Chemical Hazards 7.7.1. Nitric Acid Hazards Health Hazards Associated with Nitric Acid Nitric acid is an extremely corrosive acid capable of causing severe chemical burns very rapidly. If nitric acid mists are inhaled, health risks include corrosion of mucous membranes, delayed pulmonary edema, and even death. Contact with eyes can cause permanent cornea damage. In addition, if ingested, nitric acid can produce severe, rapid corrosive burns of the mouth, throat and gastrointestinal tract. This chemical can also react violently with certain compounds such as metallic powders and turpentine and is a strong oxidizer capable of causing fires if it comes in contact with organic material. Because of the hazards posed by nitric acid, it is important to take strict safety measures whenever handling it. Nitric Acid Safety, Handling & First Aid When handling nitric acid in the workplace, we strongly recommend you wear chemical safety glasses, a face shield for splash protection, gloves, and an approved vapor respirator if adequate ventilation is not available. As an added safety precaution, eyewash stations and washing facilities should be easily accessible. In the event of exposure to nitric acid, follow these first aid guidelines: • Inhalation - Seek fresh air and immediate medical attention. • Eye Contact - Immediately flush eyes with plenty of water for at least 15 minutes to prevent further damage, seeking medical attention immediately as well. • Skin Contact - Immediately flush affected area with plenty of water for at least 15 minutes. Remove contaminated clothing and wash with soap. Immediate medical attention is required. • Ingestion—Do NOT induce vomiting. Rinse mouth with water and give a glass of water or milk. Never give anything by mouth to an unconscious person. Seek medical attention immediately. Safe Storage & Disposal of Nitric Acid Store nitric acid in a secure area away from incompatible materials such as organic compounds, metals, alcohols or moisture. Keep container tightly closed in a cool, dry, well- ventilated area. Due to its high risk of adverse health effects, this chemical must be disposed of in accordance with federal, state, and local environmental control regulations.

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7.7.2. Ammonium Nitrate Hazards Ammonium nitrate is the ammonium salt of nitric acid. It has a role as a , an explosive and an oxidising agent. It is an inorganic molecular entity, an ammonium salt and an inorganic nitrate salt. Ammonium nitrate is commercially available both as a colorless crystalline solid and processed into prills for specific applications. Soluble in water. Does not readily burn but will do so if contaminated with combustible material. Accelerates the burning of combustible material. Produces toxic oxides of nitrogen during combustion. Used to make and explosives, and as a nutrient in producing antibiotics and yeast. Ammonium Nitrate Emulsion, Suspension, or Gel is ammonium nitrate suspended in a liquid. The material itself does not readily burn but will readily do so if contaminated by combustible material. It will accelerate the burning of combustible material. Toxic oxides of nitrogen are produced during combustion during combustion of this material. It is used as a fertilizer, as a freezing mixture, in safety explosives, matches, and pyrotechnics.

Health Hazards

Health and safety data are shown on the material safety data sheets, which are available from suppliers and can be found on the internet. Ammonium nitrate is not hazardous to health and is usually used in fertilizer products. Ammonium nitrate has an LD50 of 2217 mg/kg,[31] which for comparison is about two-thirds that of table salt. Ammonium nitrate decomposes, non-explosively, into the gaseous nitrous oxide and water vapor when heated. However, it can be induced to decompose explosively by detonation. Large stockpiles of the material can also be a major fire risk due to their supporting oxidation, a situation which can easily escalate to detonation.

Explosions are not uncommon: relatively minor incidents occur most years, and several large and devastating explosions have also occurred. Examples include the Oppau explosion of 1921 (one of the largest artificial non-nuclear explosions), the of 1947, the 2015 explosions in , and the 2020 Beirut explosions.

7.7.3. Chlorine Hazards Pure chlorine comes in two forms: gas and liquid. Chlorine gas is easily liquefied under pressure. Typically, a commercial cylinder contains liquefied gas under pressure. Chlorine gas has a disagreeable, sharp, pungent, penetrating odour. In airborne concentrations above 1000 parts per million (ppm) it has a greenish- yellow colour. In smaller concentrations it is colourless. Chlorine gas is 21⁄2 times heavier than air and tends to flow downhill and pool in lower areas. Wind and weather, however, will cause a chlorine gas cloud to disperse, spreading it in all directions, even uphill. Liquid chlorine is a transparent, amber-coloured, oily fluid that is 11⁄2 times heavier than water. Liquid chlorine has a high compression ratio. The ratio of liquid to gas is 1 to 460, which means that 1 L of liquid chlorine expands to form 460 L of pure chlorine gas. If all the liquid chlorine in a 68 kg (150 lb.) container escaped, it would release so much pure chlorine gas that it would take 24 times the amount of air in BC Place stadium to dilute the gas concentration to 0.5 ppm, the maximum allowable concentration a person can be exposed to in an eight-hour period.

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Hazards of chlorine

Health: Chlorine is corrosive. It can burn moist body surfaces such as the eyes, nose, throat, lungs, and wet skin because it forms harmful acids when it reacts with moisture. Repeated exposure to chlorine does not produce an immunity or tolerance. Long-term exposure to low concentrations of chlorine may cause a gradual decrease in lung efficiency. A single exposure to a high concentration can cause the same effect. Chlorine gas is not visible as a greenish-yellow cloud at concentrations below 1000 ppm.

Table 7.9 : Damage due to Overpressure Exposure level (parts per million) Exposure limit Maximum allowable concentration averaged over an 0.5 ppm eight-hour period 1 ppm Maximum allowable short-term exposure (15 minutes) Immediately Dangerous to Life and Health (as 10 ppm or more published by NIOSH)

Note: The Immediately Dangerous to Life and Health (IDLH) exposure level is the point at which a person without appropriate respiratory protection could be fatally injured or could suffer irreversible or incapacitating health effects. NIOSH is the National Institute for Occupational Safety and Health in the United States.

Fire: Chlorine will not burn by itself but will support combustion.

7.7.4. Data Limitations It is also observed that little data or information (regarding physical properties required for modelling) is available about for some of the chemicals.

7.8. Effect and Consequence Analysis As a part of risk assessment study, maximum credible accident analysis (MCA) is carried out to determine the maximum loss scenario from this analysis. It is an eventuality, which is possible and will have maximum consequential distances for the hazardous chemicals under evaluation. The selection of the accident scenarios is based on the engineering and professional judgment, accident descriptions of the past in similar type of plants & the expertise in risk analysis studies. 7.8.1. Likely Failure Scenarios Few likely failure scenarios have been selected after critical appraisal of raw materials and storage inventories. Failure scenarios selected are as given in Table 7.9 below: Table 7.10 : Different Failure Scenarios S. No. Scenario Remark RM-1 Ammonia Heavy Leakage-Evaporating Puddle Toxic RM-2 Ammonia Pipeline Leakage Toxic RM-3 Chlorine Pipeline Leakage Toxic

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S. No. Scenario Remark RM-4 LPG Pipe 20 mm Line Leakage-Jet Fire Thermal Impact 7.8.2. Weather Effect The effect of ambient conditions on the impact of fire / heat radiation and GLC of hazardous / toxic material can be beneficial as well as harmful. A high wind (turbulence) can dilute the toxic material while stable environment can extend the reach of IDLH or IT (inhalation LC50 rats for products) concentration to long distance. Any inflammable gas / vapour release in turbulent weather will soon dilute the hazardous gases below LEL and thus save the disaster.

7.9. Hazardous Incident Impact The identified failure scenarios in Table 7.10 have been analysed (Using ALOHA and EFFECT Modules) for the impact zones considering damage due to thermal and toxic impacts. Similar impacts are considered for expansion units. Each incident will have Impact on the surrounding environment which in extreme case may cross plant boundary. The impact zones for various scenarios are given in Table 7.11.:

Table 7.11 : Different Failure Scenarios Scenario Scenario Impact Zone Remarks No. (m) Scenario Raw Material RM-1 Ammonia Heavy ❖ 939 IDLH; Stability Class D; Template Leakage- ❖ 3100 IDLH; Stability Class F; Template 2 Evaporating Puddle RM-2 Ammonia Pipe Line ❖ 179 IDLH; Stability Class D; Template 1 (5cm Dia.)Leakage ❖ 761 IDLH; Stability Class F; Template 2

RM-3 Chlorine Pipe Line ❖ 473 IDLH; Stability Class D; Template 1 Leakage ❖ 306 IDLH; Stability Class F; Template 2 RM-4 LPG Pipe 20 mm ❖ <10 1st Degree Burn Line Leakage-Jet Fire

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Figure 7.1 : Heavy Ammonia Spillage: Toxic Impact Zone Stability Class “D”

Figure 7.2 : Heavy Ammonia Spillage: Toxic Impact Zone Stability Class “F”

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Figure 7.3 : Ammonia Pipeline Leakage- Toxic Impact Zone Stability Class “D”

Figure 7.4 : Ammonia Pipeline Leakage- Toxic Impact Zone Stability Class “F”

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Figure 7.5 : Chlorine Pipeline Leakage- Toxic Impact Zone Stability Class “D”

Figure 7.6 : Chlorine Pipeline Leakage- Toxic Impact Zone Stability Class “F”

EQMS INDIA PVT. LTD. 248 Final EIA report for Proposed Technical Ammonium Nitrate Manufacturing Plant at DLCT- 1, Domestic Tariff Area, Gopalpur Industrial Park, Chamakhandi, Tehsil- Chatrapur, District- Ganjam, Odisha-761020 by M/s Smartchem Technologies Ltd. (STL)

7.10. Consequence Analysis Since the materials involved in this study are toxic as well as flammable/exposive, the possible scenarios are toxic impacts and Jet fire. Orange colour (IDLH) in the pictures shows predominant effect due to wind direction. Templates show proposed storage tanks failures / hazardous incidents and consequential impact zone.

7.10.1. Toxicity Toxic hazards are mainly due to Ammonia and Chlorine and other toxic chemicals leakage and the impact can cross the plant boundary (in case of mainly Ammonia and chlorine (if heavy leakage) only if not controlled in time) depending upon wind direction. Other hazardous chemicals (acids/alkali) including products (Nitric Acid intermediate product) their impact will be limited to spillage area. The acid spillage if meets metal parts will produce hydrogen which is highly flammable gas. Any person moving in area and getting splash will get the injury. In addition, the spillage will cause pollution problem. The spillage is to be collected and neutralized for toxic contents before disposal. 7.10.2. Thermal/Explosive Hazards Thermal hazards are mainly due to fuel storage and Ammonium Nitrate storage (0highly explosive. LPG jet fire impactis limited within plant boundary. Thermal impacts are limited to < 10 m only i.e., within the plant boundary limit. However, the thermal impact can go further due to domino effect. Explosion (if occurs) hazards can be devastating depending upon quantum of material involved.

7.11. Conclusions and Recommendations Risk Assessment is carried out with the objective to identify the potential hazards from bulk storage facilities. Important conclusions and recommendations arising out of the Risk Analysis for Proposed Plant are listed below. • Thermal radiation from pool fires are well within the boundary . • It is recommended that the adjacent tanks shall be thermally protected by firewater. • Use corrosion-resistant structural materials and lighting and ventilation systems in the storage area. • Storage tanks should be above ground and surrounded with dikes capable of holding entire contents. • Limit quantity of material in storage up to 80 %. • Restrict access to storage area. • Post warning signs when appropriate. • Keep storage area separate from populated work areas. • Inspect periodically for deficiencies such as damage or leaks. • Have appropriate fire extinguishers available in and near the storage area.

The following measures are suggested for reducing the risk involved in pipeline systems. 1 Preventive Maintenance: Routinely inspect and conduct preventive maintenance of equipment / facilities at the unit.

2 Instruments: All the instruments like pressure, temperature transmitters/gauges and alarms switch and safety interlocks should be tested for their intended application as per the preventive maintenance schedule. Similarly, the emergency shutdown system should be tested as per the preventive maintenance schedule.

EQMS INDIA PVT. LTD. 249 Final EIA report for Proposed Technical Ammonium Nitrate Manufacturing Plant at DLCT- 1, Domestic Tariff Area, Gopalpur Industrial Park, Chamakhandi, Tehsil- Chatrapur, District- Ganjam, Odisha-761020 by M/s Smartchem Technologies Ltd. (STL)

7.12. Occupational Health and Safety Safety in the workplace is critical to the success of running a business, no matter what size it is. All safety gears will be provided to workers and care will be taken by EMC that these are used properly by them. All safety norms will be followed.

Preventing Fires & Explosions

• Fires & explosions in boiler can also result from the ignition of volatile materials and fuels. The most hazardous procedures are during the firing- up and shutting-down procedures. Coal-fired boiler should have safeguards to ensure that unspent fuel does not accumulate and ignite. The fuel supply to boiler should be fitted with an automatic shut-off mechanism. • Operators should be trained in safe systems of work. The building should be designed to be non-combustible, with automatic fire suppression engineered or designed into the process where appropriate. • Risk assessments should be carried out to consider the potential dispersal of toxic chemicals from non-furnace processes & combustion products, and the potential impact of an explosion on the surrounding areas. • Regular safety audits should be undertaken to ensure that hazards are clearly identified, and risk-control measures maintained at an optimum level. • Boiler should not be operated beyond their safe lives/ safety limits (pressure / temperature).

7.13. Personal Protective Equipment (PPE’s) General Provisions As a supplementary protection against exposure to hazardous conditions in the industry where the safety of workers cannot be ensured by other means, such as eliminating the hazard, controlling the risk at source or minimizing the risk, suitable and sufficient PPE, having regard to the type of work and risks, and in consultation with workers and their representatives, should be used by the worker and provided and maintained by the employer, without cost to the workers.

• Items of PPE provided should comply with the relevant national standards and criteria approved or recognized by the competent authority. • Those responsible for the management and operation of the personal protection programme should be trained in the selection of the proper equipment, in assuring that it is correctly fitted to the people who use it, in the nature of the hazards the equipment is intended to protect against, and provide adequate comfort, and in the consequences of poor performance or equipment failure. • PPE should be selected considering the characteristics of the wearer and additional physiological load or other harmful effects caused by the PPE. It should be used, maintained, stored and replaced in accordance with the standards or guidance for each hazard identified at the facility and according to the information given by the manufacturer. • PPE should be examined periodically to ensure that it is in good condition.

EQMS INDIA PVT. LTD. 250 Final EIA report for Proposed Technical Ammonium Nitrate Manufacturing Plant at DLCT- 1, Domestic Tariff Area, Gopalpur Industrial Park, Chamakhandi, Tehsil- Chatrapur, District- Ganjam, Odisha-761020 by M/s Smartchem Technologies Ltd. (STL)

• Different PPE & their components should be compatible with each other when worn together. • PPE should be ergonomically designed and, to the extent practicable, should not restrict the user’s mobility or field of vision, hearing or other sensory functions. • Employers should ensure that the workers who are required to wear PPE are fully informed of the requirements and of the reasons for them, and are given adequate training in the selection, wearing, maintenance and storage of this equipment. • When workers have been informed accordingly, they should use the equipment provided throughout the time they may be exposed to the risk that requires the use of PPE for protection. • The PPE should not be used for longer than the time indicated by the manufacturer. • Workers should make proper use of the PPE provided, and maintain it in good condition, consistent with their training and be provided with the proper means for doing so. Head Protection • Any helmet that has been submitted to a heavy blow, even if there are no evident signs of damage, should be discarded. • If splits or cracks appear, or if a helmet shows signs of ageing or deterioration of the harness, the helmet should be discarded. • Where there is a hazard of contact with exposed conductive parts, only helmets made of non-conducting material should be used. • Helmets for persons working overhead should be provided with chin straps. • In addition to safety, consideration should also be given to the physiological aspects of comfort for the wearer. • The helmet should be as light as possible, the harness should be flexible and should not irritate or injure the wearer and a sweatband should be incorporated. • All protective headgear should be cleaned and checked regularly. Face & Eye Protection • Face shields or eye protectors should be used to protect against flying particles, fumes, dust and chemical hazards. • Face shields should be used in boiler operations and other hot work involving exposure to high-temperature radiation sources. Protection is also necessary against sparks or flying hot objects. Face protectors of the helmet type and the face-shield type are preferred. • With the use of face and eye protectors, due attention should be paid to greater comfort and efficiency. • The protectors should be fitted and adjusted by a person who has received training in this task. • Comfort is particularly important in helmet and hood type protectors as they may become almost intolerably hot during use. Air lines can be fitted to prevent this. • Face and eye protectors should give adequate protection at all times even with the use of corrective vision devices. • Eye protectors, including corrective lenses, should be made of appropriate high- impact material.

EQMS INDIA PVT. LTD. 251 Final EIA report for Proposed Technical Ammonium Nitrate Manufacturing Plant at DLCT- 1, Domestic Tariff Area, Gopalpur Industrial Park, Chamakhandi, Tehsil- Chatrapur, District- Ganjam, Odisha-761020 by M/s Smartchem Technologies Ltd. (STL)

Respiratory Protective Equipment • When effective engineering controls are not feasible, or while they are being implemented or evaluated, respirators, appropriate to the hazard and risk in question, should be used to protect the health of the worker. • When the hazard and risk cannot be assessed with sufficient accuracy to define the appropriate level of respiratory protection, employers should make positive pressure air supplied respiratory protective devices available. • When selecting respirators, an appropriate number of sizes and models should be available from which a satisfactory respirator can be selected. Different size and models should be available to accommodate a broad range of facial types. Workers should be fit-tested for respirators. • Respirators should be cleaned and sanitized periodically. Respirators intended for emergency use should be cleaned and sanitized after each use. • The user should be sufficiently trained and familiar with the respirator in order to be able to inspect the respirator immediately prior to each use to ensure that it is in proper working condition. Inspection may include the following: I. tightness of connections. II. the condition of the respiratory inlet and outlet covering; III. head harness; IV. valves; V. connecting tubes; VI. harness assemblies; VII. hoses; VIII. filters; IX. cartridges; X. end of service life indicator; XI. electrical components; XII. shelf life date; XIII. The proper function of regulators, alarms and other warning systems. XIV. Respirators should be properly stored. Damage may occur if they are not protected from physical and chemical agents such as vibration, sunlight, heat, extreme cold, excessive moisture or damaging chemicals. XV. Each respirator should be used with an understanding of its limitations, based on a number of factors such as the level and duration of exposure, the characteristics of the chemical and the service life of a respirator. XVI. Workers should be medically evaluated for their ability to wear a respirator safely before they are required to do so. Hearing Protection • When effective engineering controls are not feasible or while they are being implemented or evaluated, hearing protection should be used to protect the health of workers. • Hearing loss of speech frequencies may occur with elevated long-term exposure to noise. The use of hearing protectors gives the best results to users who are well

EQMS INDIA PVT. LTD. 252 Final EIA report for Proposed Technical Ammonium Nitrate Manufacturing Plant at DLCT- 1, Domestic Tariff Area, Gopalpur Industrial Park, Chamakhandi, Tehsil- Chatrapur, District- Ganjam, Odisha-761020 by M/s Smartchem Technologies Ltd. (STL)

informed of the risks and trained in their use. If earplugs are used, special attention should be paid to the proper fitting technique. • Hearing protectors should be comfortable, and the users should be trained to use them properly. Special attention should be paid to possible increased risk of accidents due to the use of hearing protectors. Earmuffs reduce the capacity to locate sound sources and prevent warning signals from being heard. This is especially true for workers with considerable hearing loss. • No model is suitable for all persons. Those wearing hearing protectors should be able to choose from alternative products that meet the attenuation criteria. Earplugs should not be the only solution as not all people can wear them. • Hearing protectors should be made available at the entrance to the noisy area and they should be put on before entering the noisy area. Noisy areas should be indicated by appropriate signs. • The attenuation of hearing protector’s works well only if they are well maintained. Good maintenance consists of cleaning, changing replaceable parts such as cushions, and overall monitoring of the state of the hearing protector. • Hearing protectors should be evaluated through an audiometric test programme for exposed workers. Protection from fall • When other measures do not eliminate the risk of falling, workers should be provided with and trained in the use of appropriate fall protection equipment, such as harnesses and lifelines. Workplaces and traffic lanes in which there are fall hazards or which border on a danger zone should be equipped with devices which prevent workers from falling into or entering the danger zone. • Devices should be provided to prevent workers from falling through floors and openings. • Safety harnesses should be worn where required and the lifeline should be attached to an adequate anchor point. • Harnesses should be chosen that are safely used with other PPE that may be worn simultaneously. • Appropriate and timely rescue should be provided when using fall-arrest equipment to prevent suspension trauma.

7.14. Occupational Health- Proposal for Surveillance • The choice and the implementation of specific measures for preventing workplace injury and ill health in the workforce depend on the recognition of the principal hazards, and the anticipated injuries and diseases, ill health and incidents. Below are the most common causes of injury and illness: • Slips, trips and falls on the same level; falls from height; unguarded machinery; falling objects. • Engulfment; working in confined spaces; moving machinery, on-site transport, forklifts and cranes. • Exposure to controlled and uncontrolled energy sources; exposure to mineral wools and fibers; inhalable agents (gases, vapors, dusts and fumes);

EQMS INDIA PVT. LTD. 253 Final EIA report for Proposed Technical Ammonium Nitrate Manufacturing Plant at DLCT- 1, Domestic Tariff Area, Gopalpur Industrial Park, Chamakhandi, Tehsil- Chatrapur, District- Ganjam, Odisha-761020 by M/s Smartchem Technologies Ltd. (STL)

• Skin contacts with chemicals (irritants acids, alkalis), solvents and sensitizers); contact with hot objects. • Fire and explosion; extreme temperatures; radiation (non-ionizing, ionizing); • Noise and vibration; electrical burns and electric shock. • Manual handling and repetitive work; failures due to automation; ergonomics. • Lack of OSH training; poor work organization. • Inadequate accident prevention and inspection; inadequate emergency first-aid and rescue facilities; lack of medical facilities and social protection • Dust may enter the systemic circulation and thereby reach the essentially all the organs of body and affects the different tissues. • Working near heavy noise generating equipment may cause hearing and blood pressure related diseases. • Continuous working and improper working position leading to pain & exhaustion.

Plan of evaluation of health of workers • By predesigned format during pre-placement and periodical examinations. • Proper schedule will be devised and followed with help of occupational health experts and doctors. • Health effects of metals used, and health hazard plans based on monthly correlation of these metal related diseases and people affected.

Schedule of medical check-up during operational phase • Comprehensive Pre-employment medical check-up for all employees • General check-up of all employees once every year. • Medical examination will be done for all the employees after retirement and all those employees with more than 5 years of service leaving the company. After retirement, medical examination facility will be provided for a period of 5 years. • Dispensary and ESI facility will be provided to all workers as applicable • All safety gears will be provided to workers and care will be taken by EMC that these are used properly by them. All safety norms will be followed

7.15. Disaster Management Plan STL is storing hazardous Chemicals (Ammonia) namely in quantity more than Threshold Limit as specified in MSIHC Rules as shown in Table above. STL should prepare Disaster Management Plan (DMP) and submit it to State authorities (State Pollution Board, Factory Inspector etc.) for approval (if required). STL is having Similar Product (Ammonium Nitrate) plant at MIDC Industrial area, Taloja, Maharashtra and have OEP (Onsite Emergency Management Plan; attached). STL may prepare similar OEP for proposed unit in consultation with Local authorities.

This DMP shall be designed based on the range, scales and effects of "Major Generic Hazards" described in the Risk Assessment and prediction of various hazardous scenarios. The DMP addresses the range of thermal and mechanical impacts of these major hazards so that potential harm to people onsite and off-site, plant and environment can be reduced to a

EQMS INDIA PVT. LTD. 254 Final EIA report for Proposed Technical Ammonium Nitrate Manufacturing Plant at DLCT- 1, Domestic Tariff Area, Gopalpur Industrial Park, Chamakhandi, Tehsil- Chatrapur, District- Ganjam, Odisha-761020 by M/s Smartchem Technologies Ltd. (STL) practicable minimum. The scenarios of loss of containment are credible worst cases to which this DMP is linked.

Capabilities of DMP

The emergency plan envisaged will be designed to intercept full range of hazards specific 'to Ammonia, Chlorine & other hazardous chemicals such as fire, explosion, major spill etc. In particular, the DMP will be designed and conducted to mitigate the losses of containment situations, which have potentials to escalate into major perils.

Another measure of the DMP's capability will be to combat small and large fires due to ignition, of flammable materials either from storage or from process streams and evacuate people from the affected areas speedily to safe locations to prevent irreversible injury.

Emergency medical aids to those who might be affected by incident heat radiation flux, shock wave overpressures and toxic exposure will be inherent in the basic capabilities.

The most important capability of this DMP will be the required speed of response to intercept a developing emergency in good time so that disasters such as explosion, major fire etc. are never allowed to happen.

Disaster Control Philosophy

The principal strategy of DMP is "Prevention" of identified major hazards. The "Identification" of the hazards will employ one or more of the techniques [e.g. Hazard and Operability Study (HAZOP), accident consequence analysis etc.]. Since these hazards can occur only in the event of loss of containment, one of the key objectives of technology selection, project engineering, construction, commissioning and operation is "Total and Consistent Quality Assurance". The Project Authority will be committed to this strategy right from the conceptual stage of the plant so that the objective of prevention can have ample opportunities to mature and be realised in practice.

The DMP or Emergency Preparedness Plan (EPP) will consist of:

• On-site Emergency Plan • Off-site Emergency Plan

Disaster Management Plan preparation under the headlines of On-site Emergency Plan and Off-site Emergency Plan is in consonance with the guidelines laid by the Ministry of Environment and Forests (MOEF) which states that the "Occupier" of the facility is responsible for the development of the On-site Emergency Plan. The Off-site Emergency Plan should be developed by the Governments district emergency authorities/district collector.

7.15.1. On-site Emergency Plan Objectives The objective of the On-site Emergency Plan should be to make maximum use of the combined resources of the plant and the outside services to

EQMS INDIA PVT. LTD. 255 Final EIA report for Proposed Technical Ammonium Nitrate Manufacturing Plant at DLCT- 1, Domestic Tariff Area, Gopalpur Industrial Park, Chamakhandi, Tehsil- Chatrapur, District- Ganjam, Odisha-761020 by M/s Smartchem Technologies Ltd. (STL)

• Effect the rescue and treatment of casualties • Safeguard other personnel in the premises • Minimise damage to property and environment • Initially contain and ultimately bring the incident under control • Identify any dead • Provide for the needs of relatives • Provide authoritative information to the news media • Secure the safe rehabilitation of affected areas • Preserve relevant records and equipment for the subsequent enquiry into the cause and circumstances of emergency

EMERGENCY LEVELS Emergencies have been classified into two categories i.e. Nature - I & Nature - II.

Nature - I Incidents likely to endanger the human lives, plant and equipment within the factory premises and can be controlled by the internal resources and in certain cases with help of Mutual Aid Scheme.

Nature - II Incidents likely to endanger the human lives, plant and equipment within the factory premises and surrounding area but cannot be controlled by local resources and requires help from the

Collector’s Office, Police Commissioner, Civil Defense Control Room, State Transport Office, Medical help etc. as laid down in the District Contingency Plan.

NATURE - I EMERGENCY

Probable Nature I Emergencies can occur due to:

• Chlorine gas release from plant installations. • Uncontrollable dry grass fire in the open area. • Huge fire in factory premises Occurrence of emergencies shall be made known to all through siren codes. The detailed emergency organisation (ON-SITE) chart is provided below.

CRITERIA FOR NATURE - II EMERGENCY

Plant Manager and & above shall declare Nature - II emergency in consultation with Main Incident Controller based on their experience and criteria as mentioned below:

• Quantity of released liquid/gases either flammable or toxic, depending upon size of vessel and failure mode. • Effectiveness of measures like i. Isolation of process ii. Fire propagation and probability of subsequent events. • Need for Evacuation of neighbouring population and Medical help from the District Contingency Plan Resources.

EQMS INDIA PVT. LTD. 256 Final EIA report for Proposed Technical Ammonium Nitrate Manufacturing Plant at DLCT- 1, Domestic Tariff Area, Gopalpur Industrial Park, Chamakhandi, Tehsil- Chatrapur, District- Ganjam, Odisha-761020 by M/s Smartchem Technologies Ltd. (STL)

Nature-II Emergencies may occur due to

• Uncontrollable heavy leakage of Chlorine from storage Cylinder (in case of STL such incident possibility is less). • Severe natural calamities like earthquake & heavy cyclone. Action Plans The Action Plan should consist of:

• Identification of Key Personnel • Defining Responsibilities of Key Personnel • Designating Emergency Control Centres and Assembly Points • Declaration of Emergency • Sending All Clear Signal • Defining actions to be taken by non-key personnel during emergency

Mutual Aid STL should have “Mutual Aid Agreement” with nearby/adjoining units including Gopalpur Port authorities to pool individual unit resources to fight adverse incidents.

STL OEP (Taloja Unit) is attached to prepare On site Disaster Management Plan before commissioning the Plant and send to authorities for approval.

7.16. Emergency/Disaster Management Plan The organizational set-up necessary for chain of commands during emergency situation in the plant is as given below

Unit Head (Operations) of the STL is the Chief Emergency Coordinator and shall be the main guiding person directing the emergency operations. He shall be assisted by:

Table 7.12 Key personnel of Onsite Emergency Plan Officers Details Chief Site Sr. GM (Production) Coordinator Coordinate and direct all the activities from Emergency site. In absence of GM (Prod.), DGM (Prod. I/II) will act as Chief Site Coordinator. Chief Maintenance GM-Maintenance Coordinator Coordinate all the maintenance activities from the Emergency Control Center. In absence of GM (Maint.), DGM (E&I)/DGM-(M & C) will act as Chief maintenance Coordinator Chief Technical GM (TS&P) Coordinator Coordinate for all the Environment Monitoring, support for Safety & Fire Fighting. In absence of GM (TS&P.), DGM (project) will act as Chief Technical Coordinator Chief Service DGM (HR) Coordinator

EQMS INDIA PVT. LTD. 257 Final EIA report for Proposed Technical Ammonium Nitrate Manufacturing Plant at DLCT- 1, Domestic Tariff Area, Gopalpur Industrial Park, Chamakhandi, Tehsil- Chatrapur, District- Ganjam, Odisha-761020 by M/s Smartchem Technologies Ltd. (STL)

Coordinate with local administration take care of transport, medical, canteen arrangements, and evacuation of people if required. In absence of DGM (HR), SM (P&A) will act as Chief Service Coordinator Chief Material GM (Material) Coordinator In absence of GM (Material), DGM (Material) will act as Material Coordinator Chief Railway GM (S&D) Traffic Coordinator In absence of GM (S&D), SM (S&D) will act as Railway Traffic Coordinator IR Coordinator Sr. Mgr (P&A) In absence of SM (P&A), Manager (IR) will act as IR coordinator Maintenance DGM (E&I) /DGM (M & C) Coordinator In absence of DGM (E&I), DGM-(M & C) will act as Maintenance Coordinator for all maintenance activity Operation DGM (Prod-I) is the Incident Controller for Pipeline System Coordinator DGM (Prod-II) is the Incident Controller for TAN Plant SM (Concerned Plant) will act as Incident Controller for the respective plants Vehicle Control & Chief Security Officer Security Personnel In absence of Chief Security Officer, Dy Mgr (Security) will act as Vehicle Control & Security Personnel deployment.

Environment Sr Mgr (E&QC) Controller In absence of SM (E&QC), Dy Mgr. (E&QC) will act as Environment Coordinator Fire & Safety Incharge (F&S) Controller In absence of Incharge (F&S), Dy Mgr. (F & S) will act as Fire & Safety Controller. Medical Mgr (Medical Services) Coordinator In absence of AM (Medical Services) the Doctor on duty (Reliever) will act as Medical Coordinator Fire Control Room Dy Mgr. (F&S) will work as ECC Incharge, Incharge (ECC) In absence of Dy Mgr. (F&S), AM (Fire) will act as Fire Control Room Incharge (ECC).

Civil Services Manager (Civil) Coordinator In absence of Manager (Civil), AM (Civil) will act as Civil Services Coordinator

Chief Service Coordinator shall contact the following senior officer stationed at Gopalpur as may be required.

Table 7.13 Key personnel of Offsite Emergency Response DISASTER MANAGEMENT KEY PERSONNEL - OFFSITE EMERGENCY RESPONSE

EQMS INDIA PVT. LTD. 258 Final EIA report for Proposed Technical Ammonium Nitrate Manufacturing Plant at DLCT- 1, Domestic Tariff Area, Gopalpur Industrial Park, Chamakhandi, Tehsil- Chatrapur, District- Ganjam, Odisha-761020 by M/s Smartchem Technologies Ltd. (STL)

OFFICERS PLACE DIVISIONAL COMMISSIONER GOPALPUR COLLECTOR & DISTRICT MAGISTRATE GOPALPUR CITY MAGISTRATE GOPALPUR DY.I.G. OF POLICE GOPALPUR SUPDT.OF POLICE (Gopalpur) GOPALPUR POLICE CONTROL ROOM (Nearest) GOPALPUR DY CHIEF INSPECTOR OF FACTORIES GOPALPUR EXECUTIVE ENGINEER (OPCB) GOPALPUR CENTRAL CONTROL ROOM (CIVIL DEFENCE) GOPALPUR FIRE BRIGADE, OLD GOPALPUR GOPALPUR FIRE BRIGADE, GOPALPUR GOPALPUR HOME GUARD GOPALPUR CIVIL SURGEON (Govt. HOSPITAL) GOPALPUR ORISSA STATE POLLUTION CONTROL BOARD GOPALPUR

7.17. Roles & Responsibilities of Key Personnel 7.17.1. Overall, In-charge-Unit Head (Operation) On getting the information about emergency from GM (Prod.) rush to incident site/ECC. Assess the overall situation and provide guidance in critical decision-making.

7.17.2. Chief Site Coordinator- Sr GM (Prod.) On getting the information about emergency from GM (Prod.) rush to incident site/ECC. Assess the overall situation and provide guidance in critical decision-making.

➢ On getting the information about emergency from SM (Concerned) Plant, inform over all In-charge P (O). ➢ Rush to the emergency site to assess the situation and decide to: o Declare emergency based on amount/extent of hazards and water/air analysis (toxic / flammable material release) and advise Incharge (F&S) for sounding emergency siren. o Review if operation shutting down is required to contain / control the hazard. o Review, evacuation from affected areas and sending the affected person to a safe place. o Advise Incident Controller and other key personnel to take necessary action. o He will interact with Chief Service Coordinator and advise him on possible effects on areas inside and outside the factory to initiate Off- Site Emergency Response Plan. o Remain in touch with Overall in-charge (P -O) and inform about the situation & actions being taken and seek his advice for the critical decisions. 7.17.3. Chief Maintenance Coordinator- GM (Maintenance) ➢ After getting information about emergency from manager concerned Plant. Inform DGM (E&I), DGM (M&C.), SM (FM & CM) and Manager (Civil). ➢ Rush to the ECC, assess the situation and facilitate Chief Site.

EQMS INDIA PVT. LTD. 259 Final EIA report for Proposed Technical Ammonium Nitrate Manufacturing Plant at DLCT- 1, Domestic Tariff Area, Gopalpur Industrial Park, Chamakhandi, Tehsil- Chatrapur, District- Ganjam, Odisha-761020 by M/s Smartchem Technologies Ltd. (STL)

➢ Coordinator-GM (Prod.), Maintenance support needed to tackle the emergency. ➢ Facilitate earth-moving equipment like Cranes, Dozers etc. required for handling the emergency through civil coordinator. ➢ Facilitate elect. isolation of the affected area, if required through DGM (E&I) ➢ Facilitate lighting arrangements at (a) affected locations and (b) Assembly points if required through DGM (E&I) ➢ Facilitate work-shop facilities with adequate manpower if required through DGM (M&C.), / SM (FM /CM). ➢ Remain in touch with Chief Site Controller and Operational Controller 7.17.4. Chief Technical Controller & Environment Coordinator- GM (TS&P) On getting the information about emergency from GM (Prod.) rush to incident site/ECC. Assess the overall situation and provide guidance in critical decision-making.

➢ Rush to the site of emergency on getting the information from SM (Concerned Plant), informs SM (Process) and identify the hazards. o Facilitate monitoring /analysis of the area inside and outside the factory if required through SM (E&QC) and keep informed Chief Site Coordinator about the results. o Remain in touch with Chief Site Coordinator / Incident controller and shift in charge for taking samples and rendering help to the plant personnel. ➢ Facilitate laboratory equipment for sampling analysis within the range of 1-2 Km in the wind direction for accurate assessment with reference to offsite disaster if required through SM (E&QC). o Inform concentration of toxic gases to Chief site coordinator, Incident controller, Chief Service Coordinator, SM (F&S) and Sr. Medical Officer. ➢ Remain in touch with overall Incharge – (P-O) and inform for any foreseen Dangers in operations and suggest remedial measures. 7.17.5. Chief Service Coordinator- DGM (HR) ➢ On getting information from the Medical Coordinator inform Chief Material Coordinator-GM (Material). Rush to the Emergency Control Centre. ➢ Assess the situation in consultation with Chief Site Coordinator and Incident Controller and ensure that casualties get adequate transport / medical help. ➢ Make arrangement to shift all the persons to the safest place if called for. ➢ Assess 'Law and Order' situation. ➢ Inform press, TV / Radio, local authorities about the severity of situation in close co-ordination with Chief site Coordinator and in consultation with Over all In- charge -P (O). ➢ Arrange to close the school and shift all the persons to the safest place. ➢ Inform the District Authority / local police station in case their help is required for evacuation of personnel / preserving law and order. ➢ Evacuation of adjoining areas and villages, if required. ➢ Remain in touch with over all In-charge - P (O) and seek his advice for the critical decisions. ➢ Arrange help from Port Authorities and Other large Industries Gopalpur and neighbouring industrial units as per the requirement of Chief Site Coordinator.

EQMS INDIA PVT. LTD. 260 Final EIA report for Proposed Technical Ammonium Nitrate Manufacturing Plant at DLCT- 1, Domestic Tariff Area, Gopalpur Industrial Park, Chamakhandi, Tehsil- Chatrapur, District- Ganjam, Odisha-761020 by M/s Smartchem Technologies Ltd. (STL)

7.17.6. Chief Railway/Port Traffic Controller- GM (S&D) ➢ Rush to the ECC after getting information from Chief Service Coordinator / on hearing siren and inform SM(S&D) about the emergency. ➢ Contact SM (UPH) / Shift Incharge Packing, assess the situation and take care of Railway traffic if required. ➢ Remain in touch with Overall Incharge (P-O) and seeks his advice for the critical decisions. 7.17.7. Chief Material Coordinator- GM (Materials) ➢ Rush to the emergency control centre on receipt of the message from Chief Service Coordinator / on hearing the emergency siren and inform DGM (Material) and Mgr. (Store) about the emergency. ➢ Get the stores opened for requirement of the Firefighting/safety and other materials, which may be required during emergency. ➢ Assess the situation in consultation with Chief site coordinator & incident controller for any material requirement /help at the affected site. ➢ He will be responsible for the arrangements of trucks for movement of bulk material if required. ➢ Remain in touch with Chief site coordinator, Incident controller, and Chief maintenance coordinator. 7.17.8. IR Coordinator – Sr Mgr (P&A) ➢ Rush to the Emergency Control Centre after getting information from the Chief Security Officer and inform In-charge about the emergency. ➢ Arrange for canteen services for personnel on duty as well as affected ones. ➢ Arrange help from Gopalpur Port and neighboring industrial units as per the requirement of Chief Site Coordinator ➢ Remain in touch with over all In-charge-P (O) informed about the situation and seek his advice for the critical decisions. 7.17.9. Operation Coordinator – DGM – (Prod. – I & II) DGM-Prod.-I is the operation coordinator for Pipeline System. DGM-Prod.-II is the operation coordinator for TAN.

➢ Rush to the spot of emergency on receipt of message from Shift In-charge Concerned Plant and inform about emergency to Chief Site Coordinator GM (Prod.), Chief Technical Coordinator GM (TS&P) and Manager Concerned Plant. ➢ Assess the situation and take over the charge from Shift In-charge & report to Chief site coordinator about the anticipated hazard. ➢ Shutting down of any section of the plant or total plant in consultation with Chief Site Coordinator. ➢ Ensure that persons working in the area are safe and isolate source of toxic release if possible. ➢ Make sure that all hot jobs have been stopped and assist Mgr/ Shift In-charge plant in normalizing emergency. ➢ Advise and assist Incharge (F&S) for providing water curtains to contain toxic release with in the plant battery.

EQMS INDIA PVT. LTD. 261 Final EIA report for Proposed Technical Ammonium Nitrate Manufacturing Plant at DLCT- 1, Domestic Tariff Area, Gopalpur Industrial Park, Chamakhandi, Tehsil- Chatrapur, District- Ganjam, Odisha-761020 by M/s Smartchem Technologies Ltd. (STL)

➢ Co-ordinate rescue operations and shift the casualties to health center ➢ Advise Chief Site Coordinator if any out side help is required. ➢ Report all significant developments to chief site coordinator. ➢ Preservation of evidence as far as possible without affecting the operation of emergency procedures to facilitate any subsequent inquiries into the causes and circumstances, which led to the emergency. ➢ Depending upon the severity of incident, ensure that adequate emergency services like Medical/Laboratory/Mechanical/Electrical etc.are summoned. ➢ Remain in touch with Chief Site Coordinator and other concerned officers. ➢ Coordinate with Chief maintenance / Chief material coordinators for assistance required at site. 7.17.10. Incident Controller Concerned Plant- Sr Mgr Concerned Plant ➢ Rush to the site of emergency after getting information from Shift In-charge assesses the situation and immediately inform o Manager (Concerned) o GM – Prod. o GM (TS&P) ➢ Take over charge from shift in charge. ➢ Ensure that persons working in the area are safe and isolate source of toxic release if possible. ➢ Make sure that all hot jobs have been stopped and assist Mgr/ Shift in-charge plant in normalizing emergency. ➢ Advise and assist Incharge (F&S) for providing water curtains to contain toxic release within the plant battery. ➢ Remain in touch with Chief Site Controller and other concerned officers. ➢ Coordinate with Chief Maintenance / Chief Material coordinators for assistance required at site. ➢ Call AM and other shift in-charges from colony if required. ➢ Depending upon the severity of incident, ensure that adequate emergency services like Medical/ Laboratory/ Mechanical/ Electrical etc.are summoned. ➢ Preservation of evidence as far as possible without affecting the operation of emergency procedures to facilitate any subsequent inquiries into the causes and circumstances, which led to the emergency 7.17.11. Sr Mgr (UPH)/Mgr. Packing/ Shift in-charge (Packing) ➢ Remain in touch with Chief Site Coordinator. ➢ Help in evacuating the personnel from Packing plant if required. 7.17.12. Manager Concerned Plant ➢ Rush to the emergency site after getting information from SM (Concerned Plant) and inform Chief Maintenance Coordinator (GM-Maint.) and DGM (prod.). o Remain in touch with SM (Plant). o Coordinate with Service depts. for assistance required at site. o Call other Shift In charges & Sr. Engineers from Colony if required. o Act as Assembly point Coordinator. Take a roll call and account for missing personnel (Including contract labor / visitors).

EQMS INDIA PVT. LTD. 262 Final EIA report for Proposed Technical Ammonium Nitrate Manufacturing Plant at DLCT- 1, Domestic Tariff Area, Gopalpur Industrial Park, Chamakhandi, Tehsil- Chatrapur, District- Ganjam, Odisha-761020 by M/s Smartchem Technologies Ltd. (STL)

7.17.13. Shift In charge (Concerned Plant) ➢ Immediately proceed to the site of emergency and assess the situation: o Emergency Control Room at 101/123 (with name and location of emergency) o Sr. Manager (Concerned plant). o Shift In-charge (Environment and Quality Control Lab) ➢ During odd hours/till arrival of Chief Fire Coordinator, shift I/C should act as chief fire coordinator. ➢ Initiate the shutting down operations for controlling the hazard if unavoidable. ➢ Cordon off the area and do not allow any body to enter the affected area without respiratory protection (In case of toxic gas leakage). ➢ Direct rescue operations with the help of fire and safety staff. ➢ Open safety Almirah for the use of plant personnel. ➢ Have regard to the need for preserving evidence that could facilitate subsequent inquiry. ➢ Advise manager of the plant to take roll call and account for missing personnel. ➢ Hand over charge of the operation to the Sr. Manager when he arrives at site. ➢ During emergency involving total failure of power and telephone system, the concerned Shift In-charge will inform the Sr. Security Officer on duty, Sr. Security Officer on duty / CSO will organize transport for sending messages (as per guidelines of Shift In-charge) through messengers / Security guards on duty. ➢ Ensure service agencies like Electrical, mechanical, instrumentation is mobilized to handle the emergencies. 7.17.14. Chief Security Officer/ Dy. Mgr. (Security) vehicle control and security personnel Deployment at the Locations ➢ Rush to the spot of emergency on getting information from Security Officer on duty and inform SM (P&A) about emergency. ➢ Arrange one emergency vehicle immediately for ECC. ➢ Keep in touch with Chief Service Coordinator, Chief Site Coordinator and Incharge (F&S). ➢ He will act as a special rescue Coordinator at the time of evacuation of employees and others if required. ➢ Alerts complete staff under his control and make it available at a known point, as per the guidance of Chief Site Coordinator / Chief Service Coordinator. ➢ He will be responsible for public announcement of the hazard on public address system if hazard spreads beyond STL’s battery limits. (CSO will keep the Public address system ready at all the time for the same) ➢ Anticipate and arrange vehicles required at emergency site in consultation with Incharge (F&S) and Chief Site Coordinator and Chief Service Coordinator. ➢ On request send vehicles for getting plant personnel / fire personnel required for emergency. ➢ Arrange vehicle in consultation with Medical Coordinator / Chief Service Coordinator for shifting injured to Gopalpur hospital.

EQMS INDIA PVT. LTD. 263 Final EIA report for Proposed Technical Ammonium Nitrate Manufacturing Plant at DLCT- 1, Domestic Tariff Area, Gopalpur Industrial Park, Chamakhandi, Tehsil- Chatrapur, District- Ganjam, Odisha-761020 by M/s Smartchem Technologies Ltd. (STL)

➢ During emergency arrange for opening of relevant gates/ barriers for easy movement of vehicles. Security Guards should be posted on these gates / barriers to prevent unauthorized entry. ➢ During emergency involving total failure of power and telephone system, the concerned Shift Incharge will inform the Dy Mgr. / AM (Security), CSO will organize transport for sending messages (as per guidelines of Shift Incharge) through messengers / Security guards on duty. ➢ Arrange transport and temporary shelters for evacuated personnel and inform the relatives of the affected personnel if required. ➢ During off-site emergency the CSO will direct district authorities to report to Overall in-charge / Chief Service Coordinator / Chief Site Controller. ➢ In case bomb threat: o Inform to Overall in-charge / Chief Service Coordinator / Chief Site Controller, Police Station (nearest) & Incharge (F&S).for necessary action. o Cordoned-off the area & inform District authorities. 7.17.15. Medical Coordinator- (Mgr- Medical Services) ➢ Rush to the medical centre on getting information from Health Centre. ➢ Depute one Medical Assistant for spot first aid. ➢ Remain in touch with Chief Service Coordinator / Incident Controller for any help required. ➢ Ensure availability of adequate first-aid/medical help and coordinatefor further medical help from outside hospitals at Gopalpur. ➢ Liaison with Chief Material Coordinator for procurement of additional emergency medicines. ➢ Liaison with CSO for transportation of the injured to GOPALPUR hospital. ➢ Take note of injured, coordinate with CSO for their shifting to health centre/ GOPALPUR, Hospital. Note: After receiving emergency message from ECC, Nursing assistant will send ambulance.

7.17.16. Fire & Safety Controller- Incharge (F&S)/ Dy. Mgr. (F&S) ➢ Rush to the spot of emergency after getting information from ECC and inform to Dy Mgr. (F&S)/ AM (Fire). ➢ Direct rescue operations under the guidance of Chief Site Coordinator/ Incident controller if required ➢ Ask additional help from C.S.O. for cordoning off the area and advise fire personnel for rescue / fire fighting if required ➢ Arrange to provide water curtains, water monitors, at affected locations if required. ➢ Organize and supervise fire-fighting operations if called or. ➢ Provide necessary respiratory equipment to personnel for emergency use. ➢ Advise Chief Site Coordinator to arrange additional help from Neighbouring Industries / Gopalpur Port if required. ➢ Give safety precautions to the personnel at rescue work.

EQMS INDIA PVT. LTD. 264 Final EIA report for Proposed Technical Ammonium Nitrate Manufacturing Plant at DLCT- 1, Domestic Tariff Area, Gopalpur Industrial Park, Chamakhandi, Tehsil- Chatrapur, District- Ganjam, Odisha-761020 by M/s Smartchem Technologies Ltd. (STL)

7.17.17. Environment Coordinator – Sr Mgr (E&QC)/Dy. Mgr. (E&QC) ➢ Rush to the spot of emergency after getting information from Laboratory and assess the situation looking the wind direction ➢ Arrange for monitoring the area with in the range of 1~2 Km in the wind direction for accurate assessment depending upon the type of emergency. ➢ Inform the result to Chief Site Coordinator, Chief Technical Controller and Overall Incharge. ➢ Remain in touch with Chief Site Coordinator and Chief Technical Controller 7.17.18. Civil Coordinator – Mgr (Civil) ➢ Rush to the ECC after getting information from Chief Maintenance Coordinator./ on hearing emergency siren. ➢ Make sufficient number of contractors, workers available to do civil jobs like filling sand bags, making bunds, closing drains, excavation etc. as required for emergency. ➢ Remain in touch with Chief Maintenance Coordinator & Incident Controller for any assistance to them. 7.17.19. Mgr. IR- To work for Public Relations under SM (P&A) If disaster takes place after General Shift hours DGM (Admin) will inform Mgr. (IR). He will rush to ‘OFFSITE EMERGENCY CONTROL CENTRE’ Aerodrome circle office at Gopalpur) for liaison with District Authorities as per requirements at site and remain in touch with Chief Service Coordinator / SM (P&A) for the instructions / advise. During General Shift hours, he will assist SM(P&A).

7.17.20. Fire Control Room In-Charge- Dy. Mgr. (F&S)/AM (Fire) (Provide safety/fire support as per guidelines of shift in-charge/shift manager) On receiving emergency message from the Incharge (F&S)/ on hearing siren. Rush to ECC and take charge of Fire Control Centre from the fire operator / fire supervisor.

➢ Assess the situation and Call fire staff from fire barrack. ➢ Immediately rush Fire Tender along with the fire crew to emergency spot. ➢ Inform Medical Centre for sending ambulance to emergency site 7.17.21. Fire Supervisor should also ensure the following ➢ Supervisor on the fire tender should park the vehicle at safe location looking to the wind direction and cordon off the area. ➢ Use water monitors/hydrants/water curtains in consultation with incident/Chief site controller. ➢ Provide respiratory equipment’s to the plant personnel. ➢ In case of liquid ammonia spillage at site, put foam (HAZMAT)/ sand on the spillage area. ➢ Remain in touch with Incharge (F&S)/Dy Mgr. (F&S) /AM (Fire) ➢ Chief Site Co-coordinator will instruct Fire Control Room In-charge for operation of “All Clear Siren” when the disaster is contained / controlled.

EQMS INDIA PVT. LTD. 265 Final EIA report for Proposed Technical Ammonium Nitrate Manufacturing Plant at DLCT- 1, Domestic Tariff Area, Gopalpur Industrial Park, Chamakhandi, Tehsil- Chatrapur, District- Ganjam, Odisha-761020 by M/s Smartchem Technologies Ltd. (STL)

➢ However, regular testing of siren & emergency buzzer plant control rooms for 2 minutes on every Monday at 13.00 hrs is being done. All clear siren will sound for 2 minutes with a continuous sound.

7.18. Post Emergency Recovery The post-emergency procedures discussed briefly below are designed to successfully manage the damage / losses of an emergency event. The focus of these procedures is to move the operation back into normal operating mode as quickly and efficiently as possible.

Immediately after the “ALL CLEAR” an emergency meeting will be held in emergency control centre to assess the loss both for men & materials, where in following will be present with attendance records, details of injured, out side situation and preparation of press release (if felt necessary)

➢ Overall In charge ➢ Chief Site Coordinator ➢ Chief Maintenance Coordinator ➢ Chief Technical & Environment Coordinator ➢ Chief Service Coordinator ➢ Chief Railway Traffic controller ➢ Operational controller ➢ Incident Controller ➢ Material Coordinator ➢ DGM (Admin) ➢ CSO ➢ Medical Coordinator ➢ Fire & Safety Controller ➢ Env. Coordinator ➢ Assembly point In-charges 7.18.1. Accident Investigation 1. As soon as possible after the emergency is over and plant operation has become normal, the investigation and analysis is to be carried out to determine the cause of the event. 2. Representatives from various disciplines will be members of the investigation and analysis team. 3. The areas of the events are to be sealed off so that tempering or alterations of the physical evidence are not likely to occur. 4. Key components are to be photographed and logged with time, place, direction etc. 5. Statements are to be taken from those who were involved with the operation or who witnessed the event. 7.18.2. Damage Assessment This phase of recovery establishes the quantum of replacement machinery considered necessary for bringing back plant to normal operation; property and personnel losses accounted and culminates in a list of necessary repair, replacement and construction

EQMS INDIA PVT. LTD. 266 Final EIA report for Proposed Technical Ammonium Nitrate Manufacturing Plant at DLCT- 1, Domestic Tariff Area, Gopalpur Industrial Park, Chamakhandi, Tehsil- Chatrapur, District- Ganjam, Odisha-761020 by M/s Smartchem Technologies Ltd. (STL) work. Insurance companies will be informed of the damage and requested to pay the compensation as per claim.

7.18.3. Cleanup and Restoration This phase will only begin once the investigation is complete. Reporting documentations are to be prepared and forwarded to appropriate authorities. Repairs clean up and restoration work to begin.

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