Risk Assessment and Disaster Management Plan
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Risk Assessment and Disaster Management Plan Proposed Expansion of Pulp Plant, VSF Plant, Sulphuric Acid Plant, Carbon Disulphide Plant and Captive Power Plant along with new Excel Fibre Plant at Village: Kumarapatnam, Taluka: Ranebennuru, District: Haveri, Karnataka M/s. Grasim Industries Ltd. Proposed Expansion of Pulp Plant, VSF Plant, Sulphuric Acid Plant, Carbon Disulphide Plant and Captive Power Plant along with new Excel Fibre Plant At Village: Kumarapatnam, Taluka: Ranebennuru, District: Haveri, Karnataka Risk Assessment Report RISK ASSESSMENT REPORT 1. RISK ASSESSMENT AND DISASTER MANAGEMENT PLAN 1.1 Risk Assessment Risk assessment is the examination of activities / products that could cause harm to people and their prosperity whether enough precautions have been taken. It is a tool to focus on risk that really matters at work place with potential to cause harm. The project proponent is required to assess risks in the work place so that a plan to control the risk can be put in work place. It is very much essential to identify the probable risks that could cause serious harm to life. Flow chart showing steps in risk assessment M/s. Grasim Industries maintains a high standard of safety in its process plants through appropriate procedures and practices but accidents do happen, and therefore, a well documented Preparedness to control such situations to minimize / prevent loss to men and material is absolutely necessary. The On–Site Emergency Plans presented here make a fair appraisal of the extent of impact, which such accidental situations may have within and outside the plant and also details the steps to taken by different agencies to control the situation. The goals of this on- site emergency plan is as follows: To minimize casualties and prevent loss of life as well as damage to property and the environment To control and contain emergencies effectively at the incipient stage itself so as to restore the plant to normal operations To preserve relevant records and equipment To collect pertinent information needed in the investigation of incidents M/s. Grasim Industries Ltd. 1 J.M. EnviroNet Pvt. Ltd. Proposed Expansion of Pulp Plant, VSF Plant, Sulphuric Acid Plant, Carbon Disulphide Plant and Captive Power Plant along with new Excel Fibre Plant At Village: Kumarapatnam, Taluka: Ranebennuru, District: Haveri, Karnataka Risk Assessment Report 1.2 Disaster Management Plan 1.2.1 Definition Disaster management aims to increase the likelihood that an area will be able to anticipate, resist or recover from the losses sustained from a hazard or other threat without external assistance. Disaster Management Plan for any unit is necessarily a combination of various actions which are to be taken in a very short time but in a present sequence to deal effectively and efficiently with any disaster, emergency or major accident with an aim to keep the loss of men, material, plant/machinery etc. to the minimum. Hence, disaster management plan is very much required to avert any disaster. A situation which goes beyond the control of available resource of the plant A situation apparently may not have much loss Risk of loss of but its long-term human lives severity can affect loss of life, production and property. Disaster Figure 7.13: Situation showing when a disaster occurs 1.2.2 Scope Disaster management conveys the important idea that protecting populations and property also involves the estimation of risks, preparation, activities which will mitigate the consequences of predictable hazards and post-disaster reconstruction in a way that will decrease vulnerabilities. An effective response to disaster begins with effective planning, but must include many other steps. Each of these steps depends on the strength of other links in the disaster management chain. An important element of mitigation is emergency planning, i.e. recognizing accidents as soon as possible, assessing the consequences of such accidents and deciding on the emergency procedures, both on-site and off-site, that would need to be implemented in the event of an emergency. 1.2.3 Objective The overall objectives of the emergency plan will be: M/s. Grasim Industries Ltd. 2 J.M. EnviroNet Pvt. Ltd. Proposed Expansion of Pulp Plant, VSF Plant, Sulphuric Acid Plant, Carbon Disulphide Plant and Captive Power Plant along with new Excel Fibre Plant At Village: Kumarapatnam, Taluka: Ranebennuru, District: Haveri, Karnataka Risk Assessment Report To localize the Risk and, if possible eliminate it To minimize the effects of the accident on people and property Ensuring efficient response and relief with a caring approach To regulate the disaster response to the benefit of the community and visitors To establish those most vulnerable and at risk Elimination should require prompt action by operations and works emergency staff using, for example, fire-fighting equipment, water sprays etc Minimizing the effects may include rescue, first aid, evacuation, rehabilitation and giving information promptly to people living nearby. Encouraging mitigation measures based on state-of-the-art technology and environmental sustainability. 1.2.4 Risks/ Hazards associated with the manmade fibre industry The most significant hazard associated with the fibre manufacturing occurs during the operational phase. Hazards during operational phase of fibre manufacturing are: Process hazards Fireṡ and explosions: Fire hazards may occur in fibre godown, sulphur godown, charcoal godown, coal yard and electric short circuit. Explosions may incur in power plant. Chemical hazards - Inhalation and dermal contact exposures to chemicals during plant operations is the prime source of such hazards which can be managed through Job safety analysis, Industrial hygiene surveys, Worker training, Work permit systems, Use of personal protective equipments, Use of toxic gas detection systems with alarms, Safety mock drills & manuals, Periodic check of tools, tanks etc. Hazardṡ in confined spaces - Accidents may vary in the facility depending on the design, on-site equipment and infrastructure. It may also include reactors. Hazards occurring in the confined areas can be managed through Developing and implementing confined space entry procedures. M/s. Grasim Industries Ltd. 3 J.M. EnviroNet Pvt. Ltd. Proposed Expansion of Pulp Plant, VSF Plant, Sulphuric Acid Plant, Carbon Disulphide Plant and Captive Power Plant along with new Excel Fibre Plant At Village: Kumarapatnam, Taluka: Ranebennuru, District: Haveri, Karnataka Risk Assessment Report Risk areas in the plant are given in table below: Table 1.1 Details of Various Risk areas in the plant S. No. Section Hazard Effected area Precautions taken Mitigation Measures 1. Viscose Caustic Soda Station and • The storage tanks are inspected periodically. • If leakage is of small quantity, cover the Leakage 2 persons • Non destructive testing of Caustic Storage Tanks spillage with sand and flush with water. From for thickness measurement once in two years & • If leakage is high, caustic lye is collected in Storage replacement of tank is planned based on the Dyke and it is pumped to other Storage Tank condition tank • The tanks are inter connected to avoid over flow • Bring down caustic lye level by • The dyke walls are provided for all the tanks to transferring to other Storage tank having contain the over flows less level • Pumping arrangement made to transfer the caustic • Use Personal Protective Appliances, Face from dyke to storage tank Mask before entering inside the danger • Level indicators provided for the storage tanks zone • Mechanical seal is provided for the transfer pump • Power supply to all motor loads cut off to avoid leakages • Activation of emergency siren to alert • Standard Operating Procedures (SOPs) for people handling Caustic are provided to Operators • Activate Emergency response team • Eye/ face wash fountains and bath facilities • If the substance has gone inside the eyes, arranged at storage and handling areas wash with plenty of water for at least 15 • PPEs are provided for the Employees & regular minutes using Eye/ face wash fountains usage is ensured • Inform crisis management team • Mock drills are conducted once in Six months. • Inform Effluent Treatment plant to take of • MSDS & Emergency plan displayed both in sudden load of caustic lye solution in the Kannada & English drain • Inform statutory agencies and nearby public. M/s. Grasim Industries Ltd. 4 J.M. EnviroNet Pvt. Ltd. Proposed Expansion of Pulp Plant, VSF Plant, Sulphuric Acid Plant, Carbon Disulphide Plant and Captive Power Plant along with new Excel Fibre Plant At Village: Kumarapatnam, Taluka: Ranebennuru, District: Haveri, Karnataka Risk Assessment Report S. No. Section Hazard Effected area Precautions taken Mitigation Measures Ammonia Refrigeration • Interlock arrangement is provided between • Activation of gas detectors in case of leak leakage section and 2 chilled water pump & compressor. Compressor • Activation of emergency siren to alert from person will trip if chilled water pump is tripped people the chillers • PPEs are provided for the Employees & regular • Use PPE’s & Air Breathing Apparatus usage is ensured. before entering inside the danger zone • Providing emergency kits for Ammonia storage / • Stop ammonia compressors handling area to attend emergency. • Close the suction and delivery valves • Eye wash fountain provided. connected to compressor or chiller • Ammonia gas detector with alarm is installed in • Activation of emergency siren to alert the Refrigeration