1591A PCCPL Laru 3D QRA Report

REV PROJECT NO. MADE BY REVD BY DATE of ISSUE 0 1591 AR/NS/SV BS 10.02.2020 1 1591 AR/NS/SV BS 19.02.2020

REV 1 PUNJAB CHEMICALS & CROP PROTECTION LTD 3D QRA LALRU 19/02/2020

1. ABBREVIATIONS ...... 3

2. EXECUTIVE SUMMARY ...... 4

3. INTRODUCTION ...... 5

4. OBJECTIVE ...... 11

5. ABOUT THE SOFTWARE ...... 11

6. SCOPE OF ASSESSMENT ...... 13

7. RESULTS AND OBSERVATION ...... 17

7.1 CONSEQUENCE ANALYSIS RESULTS ...... 17

7.2 RISK ANALYIS RESULTS ...... 28

7.3 ISO CONTOURS OF LSIR DISTRIBUTION: ...... 29

8. RECOMMENDATIONS ...... 31

9. CONCLUSION ...... 37

APPENDIX 1: FLASH FIRE ENVELOPE...... 38

APPENDIX 2: POOL FIRE ENVELOPE ...... 49

APPENDIX 3: TOXIC GAS DISPERSION ENVELOPE ...... 59

APPENDIX 4: 3D CONTOURS FOR CONSEQUENCES ...... 63

APPENDIX 5: DISASTER MANAGEMENT PLAN ...... 81

APPENDIX 6: FRAMEWORK FOR MANAGEMENT OF OCCUPATIONAL HEALTH & SAFETY ...... 104

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1. ABBREVIATIONS

ALARP As Low As Reasonably Practicable

BLEVE Boiling Liquid Expanding Vapour Explosion

DMP Disaster Management Plan

DNV Det Norske Veritas

E/E/PE Electrical/ Electronic/ Programmable Electronic

ERP Emergency Response Plan

ERT Emergency Response Team

MSDS Material Safety Data Sheet

F&G Fire & Gas

HCl Hydrochloric Acid

HSE UK Health & Safety Executive, United Kingdom

IMD Indian Meteorological Department

IPA Iso-Propyl Alcohol

IR Individual Risk

IRPA Individual Risk Per Annum

IS Indian Standard

LSIR Location Specific Individual Risk

OGP Guidelines Oil & Gas Producers Guidelines

P&ID Piping & Instrumentation Diagram

PCCPL Punjab Chemicals & Crop Protection Limited

PFD Process Flow Diagram

PM Preventive Maintenance

PPM Part Per Million

QRA Quantitative Risk Assessment

REV Revision

VCE Vapour Cloud Explosion

SCABA Self-Contained Breathing Apparatus

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2. EXECUTIVE SUMMARY

WIRE Consultants has been engaged by Punjab Chemicals & Crop Protection Ltd. for the Quantitative Risk Assessment (QRA) of their process plant at their facility in Lalru, Punjab.

Present report is the Quantitative Risk Assessment Report for the process plant based on the data and inputs provided by the PCCPL Team.

The site visit was carried out at Punjab Chemicals & Crop Protection Ltd., Lalru on 15th, by multi- disciplinary team personnel from PCCPL and Wire Consultants.

The area in Scope of the Study is “Storage Area of Lalru Facility”.

The Vapor Cloud Explosion scenarios were not credible because the area is open and highly ventilated and hence the software couldn’t generate the results for the same. Failure frequency rates were taken from the OGP Guidelines.

The cumulative IRPA value for the site is 1.79E-05 per year and lies on the threshold of low-risk region and ALARP risk region. The societal risk lies largely in ALARP region.

All the results and distance of the Heat Radiations from Jet Fire and Flash Fire, Toxic Gas Envelopes and 3D Contours are attached in the Annexures of the Report and FN Curve generated are provided in the “Results and Observation” Section.

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3. INTRODUCTION

The Client is one of the biggest Industries in India dealing with manufacturing and sales of specialty and other chemicals.

This report details the Scope of the study, Results & Observations of the Assessment.

This report has been supplied in a digital format, and therefore the copy archived at WIRE server shall be considered as the primary document. This report and related files submitted should be considered as secondary documents.

3.1 FLUID PROPERTIES The basic physical &chemical properties of the materials are given in the below table with reference to the MSDS.

Table 1- Hazardous Properties of Chemicals Maximum Operating Conditions S. Boiling Flash Auto-Ignition Terminal Fluid No. Point(◦C) Point(◦C) Temp. (◦C) PRESSURE TEMPERATURE (◦C) (Barg)

1. Methanol 64.7 11 464 30 Atm

Dimethyl 2. 37.3 -49 205 30 atm Sulfide

3. O-Xylene 143-145 31 465 30 atm

4 Formaldehyde 90-100 50-78 - 30 atm

Carbon 5 46 -30 100 30 atm disulfide

6 Ethanol 78 13 425 30 atm

Acetic 7 138-140 49 332 30 atm Anhydride

8 Toluene 110.4 12.7 535.5 30 atm

9 Acetic Acid 118 40 485 30 atm

10 Chlorine -34.6 - - 30 atm

IPA (Iso propyl 11 82 12 399 33 atm alcohol)

12 Sulphuric Acid 270-340 - - 31 atm

13 HCl 81.5 - - 32 atm

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3.2 LIST OF HAZARDOUS SUBSTANCES The hazardous substances which are expected to be stored within the facility and their intended storage capacities are summarized in the table below:

Table 2- Hazardous Chemicals with Intended Storage Capacities

Capacity Number of of Type of Above Operating Operating Name of Physical Storage # storage Storage ground/ Temperature Pressure Chemical state Tank tanks/ Tank* Underground (°C) (bar) (KL*) cylinders each

1 Methanol Liquid 1 45 MS AB 25-30 Atmospheric

Dimethyl 2 Liquid 1 15 MS AB 25-30 Atmospheric Sulfide

3 o-xylene Liquid 1 10 MS AB 25-30 Atmospheric

4 Formaldehyde Liquid 1 40 MS AB 25-30 Atmospheric

Carbon 5 Liquid 1 25 MS AB 25-30 Atmospheric Disulphide

6 Ethanol Liquid 1 12 MS AB 25-30 Atmospheric

Acetic 7 Liquid 1 30 MS AB 25-30 Atmospheric anhydride

8 Toluene Liquid 1 35 MS AB 25-30 Atmospheric

9 Acetic acid Liquid 1 10 MS AB 25-30 Atmospheric

900 kgs 10 Chlorine Gas 1 MS AB 25 9 each

11 Sulphuric Acid Liquid 1 20 MS AB 25-31 Atmospheric

12 HCL Liquid 1 40 MS AB 25-32 Atmospheric

13 IPA Liquid 1 20 MS AB 25-33 Atmospheric

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3.3 ISOLATABLE SECTIONS Isolatable sections are defined to estimate the total inventory available for a release. Isolatable Sections considered for the entire study are:

Table 3: Isolatable Sections Sl. No. Tag No. Scenario Description

Small Leak from Methanol Storage Tank

1 IS1L Medium Leak from Methanol Storage Tank

Full-bore Rupture from Methanol Storage Tank

Small Leak from Dimethyl Sulfide Storage Tank

2 IS2L Medium Leak from Dimethyl Sulfide Storage Tank

Full-bore Rupture from Dimethyl Sulfide Storage Tank

Small Leak from o-xylene Storage Tank

3 IS3L Medium Leak from o-xylene Storage Tank

Full-bore Rupture from o-xylene Storage Tank

Small Leak from Formaldehyde Storage Tank

4 IS4L Medium Leak from Formaldehyde Storage Tank

Full-bore Rupture from Formaldehyde Storage Tank

Small Leak from Carbon Disulphide Storage Tank

5 IS5L Medium Leak from Carbon Disulphide Storage Tank

Full-bore Rupture from Carbon Disulphide Storage Tank

Small Leak from Ethanol Storage Tank

6 IS6L Medium Leak from Ethanol Storage Tank

Full-bore Rupture from Ethanol Storage Tank

Small Leak from Acetic anhydride Storage Tank

7 IS7L Medium Leak from Acetic anhydride Storage Tank

Full-bore Rupture from Acetic anhydride Storage Tank

Small Leak from Toluene Storage Tank

8 IS8L Medium Leak from Toluene Storage Tank

Full-bore Rupture from Toluene Storage Tank

Small Leak from Chlorine Tonner 9 IS9V Medium Leak from Chlorine Tonner

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Sl. No. Tag No. Scenario Description

Full-bore Rupture from Chlorine Tonner

Small Leak from IPA Storage Tank

10 IS10L Medium Leak from IPA Storage Tank

Full-bore Rupture from IPA Storage Tank

Small Leak from Acetic Acid Storage Tank

11 IS11L Medium Leak from Acetic Acid Storage Tank

Full-bore Rupture from Acetic Acid Storage Tank

Small Leak from HCl Storage Tank

12 IS12V Medium Leak from HCl Storage Tank

Full-bore Rupture from HCl Storage Tank

Small Leak from Sulfuric Acid Storage Tank

13 IS13L Medium Leak from Sulfuric Acid Storage Tank

Full-bore Rupture from Sulfuric Acid Storage Tank

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3.4 MODEL OF FACILITY The plot plan of the facility is shown below:

Figure 1: Plot Plan of the Lalru Facility, PCCPL

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The snapshots of 3D model prepared for the facility and used for the analysis are shown below, for reference.

Figure 2: South-East Bird-Eye View of Model

Figure 3: North-East Bird-Eye View of Model

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4. OBJECTIVE

The main objective for conducting this Quantitative Risk Assessment (QRA) study is to determine the potential risks and their consequences to the facility due to storage and transferring of hazardous chemicals at various locations and other equipment. This is achieved by the following:

• Identification of hazards that could be realized from hazardous material. • Identify the potential failure scenarios that could occur within the facility. • To asses, the potential risks associated with identified hazards to which the plant and its personnel and community outside may be subjected. Consequence analysis of various hazards is carried out to determine the vulnerable zones for each probable accident scenario. • Evaluate the process hazards emanating from the identified potential accident scenarios. • Analyse the damage effects to the surroundings due to such accidents. • Conclusion and Recommendations in order to mitigate the hazard.

5. ABOUT THE SOFTWARE

PHAST (Process Hazard Analysis Software Tool) is a comprehensive consequence analysis tool. It examines the process of a potential incident from the initial release to far field dispersion, including modelling of pool vaporization and evaporation, and flammable and toxic effects. It can simulate various release scenarios such as leaks, line ruptures, long pipeline releases and tank roof collapse in pressurized / unpressurised vessels or pipes.

• Phast is the industry standard process hazard analysis tool for the analysis of flammable, fire, explosion and toxic hazards, used by over 800 organizations globally

• The process safety management software incorporates groundbreaking model development research work conducted with process industry partners

• Phast process hazard analysis software has been continuously developed by experts for over 30 years

• Worldwide technical support and training is available for improved process safety management

PHAST has an inbuilt event tree for determining the outcomes which are based on two types of releases namely continuous and instantaneous. Leaks are considered to be continuous releases whereas, ruptures are considered to be instantaneous releases. These types of releases are further classified into those which have a potential for rain-out and those which do not. Whether the release would leak to a rain-out or not depends upon droplet modeling which is the main cause of formation of pools. Following figure present the event tree utilized by PHAST to generate the event outcomes.

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The DNV PHAST/ SAFETI software suite performs calculations using empirical correlations. However, considering the requirement of detailed and exhaustive risk assessment, CFD-based modeling was used in addition to the DNV PHAST based calculations. The software suite offered as Pyrosim Software by Thunderhead Engineering was utilized to generate 3D geometry and to plot 3D contours. Pyrosim is a general-purpose computer program for the steady-state simulation. One of the primary strengths of the program is its built-in capability to calculate multi-component multi-phase equilibria, along with the automatic performance of energy-balance calculations. This predictive ability allows the program to simulate novel processes rather accurately. The in-built FDS (Fire Dynamics Simulator) available within calculation core helps in dynamic state analysis and visualization of complex phenomena such as fires etc. and overcomes the shortcomings of empirical correlations. The 3D Geometry was created in Autodesk 3D Environment and was imported in the Pyrosim software and was later refined for ease of calculations.

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6. SCOPE OF ASSESSMENT

6.1 CONSEQUENCE IMPACT ANALYSIS Typically, a QRA (Consequence Analysis or Quantitative Risk Assessment) can be defined as the formal and systematic approach of identifying potentially hazardous events, estimating the likelihood and consequences of those events. The following methodology was followed for Quantitative Risk Assessment.

• Step 1: Pre-modelling Data Collection Data was requested related to process/ plant information for the risk assessment, for example, site location, environment, weather data, PFDs and P&IDs, process conditions etc.

• Step 2: Hazard Identification and Scenario Selection after a detailed study of the data, identification of hazards was carried out using inventory listing and engineering judgement based on the inventories and information on operating conditions in different storages etc.

The study covered both fire/ explosion hazards and toxic hazards as applicable. The hazards (AS RELEVANT) which were investigated are as below: ➢ Pool fire ➢ Jet fire ➢ Vapor Cloud Explosion ➢ Fireball / BLEVE ➢ Unignited dense cloud dispersion ➢ Toxicity hazard

• Step 3: Consequence Analysis

Any incident can have more than one outcome. For the chosen scenarios, consequence analysis is conducted using DNV- PHAST which involved: ➢ Determination of source strength ➢ Thermal loads at various distances due to pool fire, BLEVE and jet flame was computed, and consequence distances were identified (Immediate ignition case) ➢ Cloud contour concentration as a function of distance from source, amount of flammable material between two explosive limits, overpressures if any due to explosion were calculated as a function of the distance from the center of explosion. (Delayed Ignition case). ➢ Dispersion calculations for the airborne toxic chemicals (as relevant) were carried out to arrive at the damage distances and impact zones for the chosen threshold values (Damage Criteria). For dispersion modelling, predominant influencing factors being the wind speed and stability class, typical wind speeds and stability classes for the region were considered. Two sets of stability class and wind velocity combinations were used one representing typical day conditions and the other night conditions.

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6.2 Damage Criteria Damage criteria for the study was based on ➢ Thermal radiation ➢ Overpressure ➢ Exposure to Toxic Substances.

• Step 4: Likelihood Estimation

In order to calculate the release probabilities for the considered scenarios, the failure frequencies shall be calculated using various data banks.

• Step 5: Risk Estimation

Risk estimation shall be carried out using PHAST Risk Package. Results shall be expressed in terms of LSIR Contours and F-N Curve.

• Step 6: Recommendations

The major risk contributors shall be listed out. Recommendations would then be made in order to reduce the risk to As Low as Reasonably Practicable (ALARP) Levels as per UK HSE criteria. Company’s internal criteria for ALARP can also be utilized if the data is shared by company before project initiation.

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6.3 WIND CHARACTERISTICS Weather Data for the study will be taken from the Indian Meteorological Department (IMD) and the Weather Stability Class table is:

Table 4: Pasquill Stability Class:

Stability Class Definition Stability Class Definition

A Very Unstable D Neutral

B Unstable E Slightly Stable

C Slightly Unstable F Stable

Following wind speed and stability class is considered based on Wind Rose given in the figure 1 below.

• 1.5F - F stability class and wind speed of 1.5m/sec

• 5D - D stability class and wind speed of 5m/sec

Considering the same, the above weather conditions were used for modelling purposes.

Figure 4: Wind Rose for Lalru, Punjab

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Wind direction probabilities based on the above wind rose are given in following table:

Table 5: Wind Direction Probabilities

Wind

E E S

N N

W W

ESE SSE

ENE ENE NNE

Direction SSW

NNW Total

WSW WSW WNW WNW

Wind

Speed (1.5

0.020 0.020 0.021 0.025 0.012 0.013 0.010 0.011 0.021 0.016 0.024 0.019 0.026 0.013 0.014 0.010 0.273 m/s) 0.017

Wind

Speed (5.0

0.129 0.129 0.161 0.044 0.015 0.011 0.010 0.014 0.022 0.022 0.043 0.071 0.096 0.035 0.015 0.012 0.727 m/s) 0.027

Total

0.044 0.044 0.149 0.182 0.069 0.027 0.024 0.021 0.025 0.043 0.038 0.066 0.090 0.122 0.048 0.029 0.023 1.000

6.4 ATMOSPHERIC CONDITIONS The following atmospheric parameters are considered as input for consequence modeling:

1) Ambient temperature: 240C (Average annual temperature)

2) Relative humidity: 71% (Average annual relative humidity)

3) Average Solar Radiation Flux: 0.21kW/m2

(The above data and figures are extracted from relevant tables from IMD, India)

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7. RESULTS AND OBSERVATION

7.1 CONSEQUENCE ANALYSIS RESULTS

7.1.1 Flash Fire Concentration Distances (all hole sizes): Table 6: Summary for Flash Fire Results Distance to LFL fraction Scenario Hole Size Weather Distance to LFL [m] [m]

1.5/F 1 2 7mm 5/D 1 2

1.5/F 6 12 IS-1L 25mm 5/D 1 2

1.5/F 20 36 FBR 5/D 7 13

1.5/F 1 1 7mm 5/D 1 2

1.5/F 15 21 IS-2L 25mm 5/D 6 14

1.5/F 78 103 FBR 5/D 26 46

1.5/F 1 1 7mm 5/D 2 2

1.5/F 1 1 IS-3L 25mm 5/D 1 1

1.5/F 14 22 FBR 5/D 9 16

1.5/F 1 1 7mm IS-4L 5/D 1 1

25mm 1.5/F 1 2 17

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Distance to LFL fraction Scenario Hole Size Weather Distance to LFL [m] [m]

5/D 1 1

1.5/F 6 12 FBR 5/D 4 6

1.5/F 6 8 7mm 5/D 2 2

1.5/F 19 26 IS-5L 25mm 5/D 11 19

1.5/F 106 141 FBR 5/D 36 63

1.5/F 1 1 7mm 5/D 1 2

1.5/F 5 7 IS-6L 25mm 5/D 1 1

1.5/F 18 28 FBR 5/D 7 14

1.5/F 1 1 7mm 5/D 1 1

1.5/F 1 1 IS-7L 25mm 5/D 1 1

1.5/F 4 7 FBR 5/D 1 4

1.5/F 1 1 7mm IS-8L 5/D 2 2

25mm 1.5/F 6 9

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Distance to LFL fraction Scenario Hole Size Weather Distance to LFL [m] [m]

5/D 1 2

1.5/F 41 57 FBR 5/D 12 23

1.5/F NA NA 7mm 5/D NA NA

1.5/F NA NA IS-9V 25mm 5/D NA NA

1.5/F NA NA FBR 5/D NA NA

1.5/F 1 1 7mm 5/D 1 2

1.5/F 8 11 IS-10L 25mm 5/D 1 2

1.5/F 37 52 FBR 5/D 12 22

1.5/F 1 1 7mm 5/D 1 1

1.5/F 1 3 IS-11L 25mm 5/D 1 1

1.5/F 5 10 FBR 5/D 3 6

1.5/F NA NA 7mm IS-12V 5/D NA NA

25mm 1.5/F NA NA

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Distance to LFL fraction Scenario Hole Size Weather Distance to LFL [m] [m]

5/D NA NA

1.5/F NA NA FBR 5/D NA NA

7.1.2 Jet Fire Radiation Distances (all hole sizes) Table 7: Summary for Jet Fire Results

Distance Distance Distance downwind Scenario Hole Size Weather downwind (4 downwind (12.5 (37.5 kW/m2) [m] kW/m2) [m] kW/m2) [m]

1.5/F NR NR NR 7mm 5/D NR NR NR

1.5/F NR NR NR IS-1L 25mm 5/D 3 NR NR

1.5/F 22 NR NR FBR 5/D 19 16 NR

1.5/F 3 NR NR 7mm 5/D 2 NR NR

1.5/F 10 9 NR IS-2L 25mm 5/D 8 6 6

1.5/F 46 38 32 FBR 5/D 39 32 27

1.5/F NR NR NR 7mm 5/D NR NR NR IS-3L 1.5/F NR NR NR 25mm 5/D NR NR NR

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Distance Distance Distance downwind Scenario Hole Size Weather downwind (4 downwind (12.5 (37.5 kW/m2) [m] kW/m2) [m] kW/m2) [m]

1.5/F 8 6 NR FBR 5/D 7 5 4

1.5/F NR NR NR 7mm 5/D NR NR NR

1.5/F NR NR NR IS-4L 25mm 5/D NR NR NR

1.5/F 13 NR NR FBR 5/D 16 NR NR

1.5/F NR NR NR 7mm 5/D NR NR NR

1.5/F 7 7 NR IS-5L 25mm 5/D 6 5 NR

1.5/F 35 30 NR FBR 5/D 29 25 21

1.5/F NR NR NR 7mm 5/D NR NR NR

1.5/F 3 NR NR IS-6L 25mm 5/D 2 NR NR

1.5/F 17 14 NR FBR 5/D 15 12 11

1.5/F NR NR NR 7mm IS-7L 5/D NR NR NR

25mm 1.5/F NR NR NR

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Distance Distance Distance downwind Scenario Hole Size Weather downwind (4 downwind (12.5 (37.5 kW/m2) [m] kW/m2) [m] kW/m2) [m]

5/D NR NR NR

1.5/F 6 NR NR FBR 5/D 5 4 NR

1.5/F NR NR NR 7mm 5/D NR NR NR

1.5/F 2 NR NR IS-8L 25mm 5/D 2 NR NR

1.5/F 14 12 10 FBR 5/D 13 10 8

1.5/F NA NA NA 7mm 5/D NA NA NA

1.5/F NA NA NA IS-9V 25mm 5/D NA NA NA

1.5/F NA NA NA FBR 5/D NA NA NA

1.5/F NR NR NR 7mm 5/D NR NR NR

1.5/F 3 NR NR IS-10L 25mm 5/D 3 NR NR

1.5/F 17 14 NR FBR 5/D 15 12 11

1.5/F NR NR NR IS-11L 7mm 5/D NR NR NR

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Distance Distance Distance downwind Scenario Hole Size Weather downwind (4 downwind (12.5 (37.5 kW/m2) [m] kW/m2) [m] kW/m2) [m]

1.5/F NR NR NR 25mm 5/D NR NR NR

1.5/F 9 NR NR FBR 5/D 8 8 NR

1.5/F NA NA NA 7mm 5/D NA NA NA

1.5/F NA NA NA IS-12V 25mm 5/D NA NA NA

1.5/F NA NA NA FBR 5/D NA NA NA

7.1.3 Pool Fire Radiation Distances (all hole sizes): Table 8: Summary for Pool Fire Results

Distance Distance Distance Scenario Hole Size Weather downwind (4 downwind (12.5 downwind (37.5 kW/m2) [m] kW/m2) [m] kW/m2) [m]

1.5/F 8 4 NR 7mm 5/D 9 5 NR IS-1L 1.5/F 26 16 NR (Methanol 25mm 5/D 26 18 NR Storage Tank) 1.5/F 117 76 48 FBR 5/D 116 81 46

1.5/F 8 4 3 IS-2L 7mm 5/D 8 5 3

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Distance Distance Distance Scenario Hole Size Weather downwind (4 downwind (12.5 downwind (37.5 kW/m2) [m] kW/m2) [m] kW/m2) [m]

(Dimethyl 1.5/F 29 17 7 Sulfide 25mm 5/D 28 19 8 Storage Tank) 1.5/F 142 86 45 FBR 5/D 138 90 56

1.5/F 25 16 7 7mm 5/D 27 18 10 IS-3L 1.5/F 80 49 27 (o-xylene 25mm 5/D 81 53 35 Storage Tank) 1.5/F 183 113 65 FBR 5/D 186 121 80

1.5/F NA NA NA 7mm 5/D NA NA NA IS-4L 1.5/F NA NA NA (Formaldehyde 25mm 5/D NA NA NA Storage Tank) 1.5/F NA NA NA FBR 5/D NA NA NA

1.5/F 6 3 NR 7mm 5/D 7 3 NR IS-5L 1.5/F 22 11 6 (Carbon Di- 25mm Sulfide 5/D 22 13 6 Storage Tank) 1.5/F 45 24 11 FBR 5/D 49 32 11

IS-6L 7mm 1.5/F 12 7 4 24

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Distance Distance Distance Scenario Hole Size Weather downwind (4 downwind (12.5 downwind (37.5 kW/m2) [m] kW/m2) [m] kW/m2) [m]

(Ethanol 5/D 12 9 5 Storage Tank) 1.5/F 38 23 11 25mm 5/D 37 25 11

1.5/F 100 63 33 FBR 5/D 101 68 38

1.5/F 12 6 NR 7mm 5/D 14 8 NR IS-7L 1.5/F 37 21 12 (Acetic 25mm Anhydride 5/D 39 26 12 Storage Tank) 1.5/F 137 84 45 FBR 5/D 141 96 45

1.5/F 21 13 5 7mm 5/D 22 16 7 IS-8L 1.5/F 38 16 NR (Toluene 25mm 5/D 43 22 NR Storage Tank) 1.5/F 98 45 NR FBR 5/D 119 45 NR

1.5/F NA NA NA 7mm 5/D NA NA NA IS-9V 1.5/F NA NA NA (Chlorine 25mm 5/D NA NA NA Tonner) 1.5/F NA NA NA FBR 5/D NA NA NA 25

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Distance Distance Distance Scenario Hole Size Weather downwind (4 downwind (12.5 downwind (37.5 kW/m2) [m] kW/m2) [m] kW/m2) [m]

1.5/F 14 9 4 7mm 5/D 15 10 5 IS-10L 1.5/F 45 28 13 (IPA Storage 25mm 5/D 44 30 15 Tank) 1.5/F 148 93 52 FBR 5/D 148 98 64

1.5/F 9 5 NR 7mm 5/D 10 5 NR IS-11L 1.5/F 27 14 NR (Acetic Acid 25mm 5/D 29 17 NR Storage Tank) 1.5/F 62 36 NR FBR 5/D 65 44 NR

1.5/F NA NA NA 7mm 5/D NA NA NA IS-12V 1.5/F NA NA NA (HCl Storage 25mm 5/D NA NA NA Tank) 1.5/F NA NA NA FBR 5/D NA NA NA

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7.1.4 Toxic Gas Dispersion Distances (all hole sizes): Table 9: Summary for Toxic Gas Dispersion Results Distance downwind Distance downwind to Scenario Hole Size Weather to STEL [m] IDLH [m]

1.5/F >1000 40 7mm 5/D >1000 9 IS-5L 1.5/F >1000 100 (Carbon Di- 25mm Sulfide Storage 5/D >1000 50 Tank) 1.5/F >1000 361 FBR 5/D >1000 185

1.5/F >1000 >1000 7mm 5/D >1000 >1000 IS-9V 1.5/F >1000 >1000 (Chlorine 25mm 5/D >1000 >1000 Tonner) 1.5/F >1000 >1000 FBR 5/D >1000 >1000

1.5/F >1000 >1000 7mm 5/D >1000 >1000 IS-12V 1.5/F >1000 >1000 (HCl Storage 25mm 5/D >1000 >1000 Tank) 1.5/F >1000 >1000 FBR 5/D >1000 >1000

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7.2 RISK ANALYIS RESULTS

7.2.1 LOCATION-SPECIFIC INDIVIDUAL RISK

The LSIR (location-specific-individual risk) was determined by software-based calculations and the contour for the same is provided in Figure- 1 below. It can be observed that the maximum value of iso- contour is 1E-05 per year within the facility under study.

7.2.2 INDIVIDUAL RISK PER ANNUM

Based on the location-specific individual risk, individual risk per annum value is calculated for the different population categories. Since the facility is still in early design stage, the population categories were defined in terms of generic working groups and the IR values for each such group depending on the amount of time they spent in the process areas were calculated. The IR values for all of the population categories are in the range of or less than 1E-05 per year within the facility under study.

The Cumulative IRPA value for the site is 1.79E-05 per year and lies on the threshold of low-risk region and ALARP risk region.

7.2.3 SOCIETAL RISK

The societal risk calculation was carried out using the software-based modeling and calculations. The same is represented through F-N Curve and is provided in Figure-2. It can be observed that the societal risk distribution lies within ALARP region of societal risk.

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7.3 ISO CONTOURS OF LSIR DISTRIBUTION:

Figure 5: LSIR Contour for the Facility

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Figure 6: FN Curve for the PCCPL, Lalru

Note: The above figure represents the Societal Risk associated with the facility.

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8. RECOMMENDATIONS

Storage, Handling & Transportation of Toluene

• Following mitigation measures will be followed in case of Toluene Leakage:

- Evacuate the immediate vicinity and cordon off the entry points. - Water curtains, if available, shall be immediately activated. - The open/close positions of drain valve shall be checked to ensure that run-off toluene is not going to adjacent process areas - Practice use of dedicated spill-kit for controlling the spill. - If the spill kit is not readily available, absorb the spilled chemical with dry soil, sand or other non- combustible material. - Only trained ERT (emergency response team) members will be allowed to work in this area. - SCBA sets shall be kept standby to ensure easy and quick rescue.

• Following Safety Measures will be made available to avoid Emergencies related to Toluene Leakage:

- Dedicated gas detectors shall be provided to identify the leak at insipient stage - Toluene handling area will be well ventilated. - DRY earth, sand or other non-combustible material is/will be provided at shed. - Safety shower and eye wash station will be available in Toluene shed area. - Working of zero static charge generation will be ensured. - Full body protection suite and other PPEs shall be kept ready. - Safe Operating procedures and Emergency Response Procedures will be followed strictly. - Only trained workers and employee shall be allowed to work for tank loading and unloading. - Regular worksite inspection will be carried out. - Jumper setting to inlet and out let pipeline will be provided. - Additional dump tank shall be provided for emergency situation.

Storage, Handling & Transportation of Chlorine

• Following mitigation measures shall be followed in case of Chlorine Leakage:

- Evacuate area as soon as possible. - Do not direct water at spill or source of leak. - Absorb the fumes through Chlorine Hood with blower. - Only trained ERT (emergency response team) members will be allowed to work in this area. - SCBA sets shall be kept standby to ensure easy and quick rescue.

• Following Safety Measures will be made available to avoid Emergencies related to Chlorine Leakage:

- Chlorine handling area shall be well ventilated. - Chlorine Hood with blower shall be provided with scrubbing arrangement.

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- SCBA sets shall be kept ready at chlorine handling area. - Empty & filled cylinders shall be stored separately. - Spare Oxygen Cylinder for SCBA sets shall be kept available. - Safety shower and eye wash station will be available in Chlorine shed area. - Online Cl2 gas detectors shall be installed at conspicuous locations inside the plant. - Alarms shall be configured for detection of chlorine in office area and control room. - Breathing air network shall be available in entire operational area. - Full body protection suite and other PPEs shall be kept ready. - Safe Operating procedures and Emergency Response Procedures will be followed strictly. - Only trained workers and employers shall be allowed to work in this area. - Regular worksite inspection will be carried out.

Storage, Handling & Transportation of Carbon Di-sulphide

• Following mitigation measures shall be followed in case of Carbon Di-sulphide Leakage:

- Evacuate the immediate vicinity and cordon off the entry points. - Water curtains, if available, shall be immediately activated. - Only trained ERT (emergency response team) members will be allowed to work in this area. - SCBA sets shall be kept standby to ensure easy and quick rescue. - Cut off the power supply for all electrical and electronic assemblies in the vicinity as the auto- ignition temperature of the chemical is very low - The entry of automobiles shall be prohibited in the surrounding

• Following Safety Measures will be made available to avoid Emergencies related to Chlorine Leakage:

- Water sprinkling around the tank shall be installed. - Working of thermometer on storage tank shall be checked twice a day. - Working of pressure relief valve and bursting disk shall be checked periodically. - Hot job should not be permitted near storage tank area. - Dedicated gas detectors shall be provided - The tank shall be submersed in the water so that any leak from flange or body shall not release to atmosphere - For any significant leak, self-contained breathing mask with full face should be used by all persons entering contaminated area. - Wear special protective clothing. - Isolate for 700-800m in all directions if tank car or truck is involved in fire during transportation

Storage, Handling & Transportation of Methanol, Ethanol & IPA

• If the methanol is ingested by an individual, do not induce vomiting. Volatile chemicals have a high risk of being aspirated into the victim's lungs during vomiting which increases the medical problems.

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• If the victim is conscious and not convulsing, give a couple of glasses of water to dilute the chemical and immediately call a hospital or poison control center.

• If the victim is convulsing or unconscious, do not give anything by mouth, ensure that the victim's airway is open and lay the victim on his/her side with the head lower than the body.

• Use of water spray when fighting fire may be inefficient. For small fires, Dry chemical, CO2, water spray or alcohol-resistant foam shall be utilized.

• For large fires, Water spray, fog or alcohol-resistant foam shall be practiced. Move containers from fire area if you can do it without risk.

• For fire involving tanks or car/trailer loads, facilitate fire-fighting from maximum distance or use unmanned hose holders or monitor nozzles. Cool containers with flooding quantities of water until well after fire is out. Withdraw immediately in case of rising sound from venting safety devices or discoloration of tank

Storage, Handling & Transportation of Dimethyl Sulfide

• This chemical is a combustible liquid. Poisonous gases including hydrogen sulfide and sulfur oxides are produced in fire. Use dry chemical, carbon dioxide, water spray, fog, or foam extinguishers.

• Wear self-contained breathing apparatus and full protective clothing.

• If it can be done safely, move container from fire area.

• Isolate and cordon off the surrounding for any leak associated with tank truck responsible for transportation of the said chemical

Storage, Handling & Transportation of Acetic Anhydride & Glacial Acetic Acid

• When material is not involved in fire, do not use water on material itself for spill control

• For cases of ingestion, do not induce vomiting. Corrosive chemicals will destroy the membranes of the mouth, throat, and esophagus and, in addition, have a high risk of being aspirated into the victim's lungs during vomiting which increases the medical problems. If the victim is conscious and not convulsing, give a couple of glasses of water to dilute the chemical and contact a hospital or poison control center

• For extinguishment of small fire, prefer use of Dry chemical or CO2 based extinguishers.

• Move containers from fire area if you can do it without risk.

• For any major fire, flood fire area with large quantities of water, while knocking down vapors with water fog. If water supply is inadequate, arresting the vaporized inventory shall be the priority.

• For fire involving tanks or car/trailer loads, Cool containers with flooding quantities of water until well after fire is out. Do not get water inside containers. Withdraw immediately in case of rising sound from 33

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venting safety devices or discoloration of tank

Storage, Handling & Transportation of HCL & Sulfuric Acid

Manual Handling of Drums or Barrels

• Layout and location of hazardous chemical storage area shall be based on natural and Mechanical ventilation.

• Spare barrels of sufficient quantity will be kept ready for any emergency spillage or leakage.

• Regular inspection of all the drums of hazardous chemicals shall be carried out and damaged drums shall be separated and disposed to avoid the possibility of catastrophic rupture.

• Display Boards shall be provided on all storage drum which include the name of the chemicals, material of construction, Calibration of tanks and date of Painting.

• All equipment related to hazardous chemical storage shall be maintained and calibrated regularly.

• Drum trolley will be used for the movement of drums of hazardous chemicals to avoid accident due to manual error.

• SOP for handling hazardous chemicals will be displayed in local language for safe operating procedure.

• Proper inventory of hazardous chemicals will be maintained and buffer stock will be kept as minimum as possible.

• Standard procedure for unloading will be in place and will be implemented for safe unloading of road tanker.

• Water showering system (Automated sprinkling system) will be provided to the flammable liquid storage area, wherever required to avoid the vaporization due to increase in atmosphere temperature.

• First aids boxes will be provided at prominent places in the plant.

• Area is/will be declared as ‘NO SMOKE ZONE’. Necessary safety signboards shall be displayed.

Manual Handling of Gas Cylinders

• Store cylinders upright with valve outlet seals and valve protection caps in place.

• Store cylinders in accordance with ISO Standard 11625. 34

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• Full and empty cylinders should be segregated and stored separately.

• Visually inspect stored cylinders on a routine basis, or at least weekly, for any indication of leakage or problems

• Use of approved regulators for the specific gas.

• Move cylinders using a suitable hand truck or cart.

• Use a cylinder cage or cradle to lift a cylinder

Chemical Fume Hood

• Verify exhaust system is operating before working in the hood. Monitor the dial to verify continued operation.

• Procedures which involve the liberation of volatile, flammable or toxic materials must be performed in a fume hood.

• Work well inside the hood: minimally, six (06) inches from the face.

• Maintain a sash height as feasible within the guidelines of the inspection for the manipulations performed.

• Do not block the air exit slots at the lower rear of the hood.

• Large equipment in the hood creates potentially dangerous zones of turbulence. If this use is necessary, the hood should be so dedicated and not used for other purposes.

• Keep your head outside the fume hood.

• Do not overcrowd or clutter the fume hood.

• Do not store chemicals in the fume hood.

Management of Process Safety

• Use of mechanical equipment & tools that easily generate sparks in operation should be prohibited in the areas where flammable inventories such as isopropyl alcohol, carbon disulfide etc. are handled.

• Attention should be given to avoid possible sources of ignition. Ensure strict implementation of ‘NO SMOKING’ and ‘NO MOBILE’ at the facility to minimize ignition chances. The vehicles entering inside the plant should be ensured to be fitted with flame arrestors.

• To ensure due emergency preparedness, necessary simulations through periodic mock drills for different types of credible emergencies shall be carried out.

• A dedicated emergency response plan (ERP) shall be prepared for the site during the detailed design stage. Necessary QRA study or Fire & Explosion Study shall be carried during detailed design stage to provide inputs for the QRA study 35

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• The preventive maintenance (PM) strategy for the storage tanks and associated safety systems including relief valve(S) shall be reviewed considering the operating life and due provisions shall be ensured to maintain the relief valves in operating condition. Additional precautions shall be undertaken for the storage tank for carbon disulfide.

• Dedicated F&G Mapping Study shall be performed in detailed design stage to determine the coverage and protection provided by the gas detectors in accordance with IS.TR.84.00.07 (guideline for performance-based F&G Mapping). Due redundancy shall be practiced for the detection system for the equipment containing chlorine and carbon disulfide.

• It is recommended to keep the storage tank of carbon disulfide immersed in water so that any leak or run-off would not directly come in contact with air.

• Hazardous area classification study shall be carried out in detailed design stage to ensure that E/E/PE (electrical/ electronic/ programmable electronic) equipment and assemblies are designed, procured and maintained as per requirements of prevailing hazardous zone as per IS 5571 and IS 5572.

• Necessary means of spill control or arresting of leak shall be provided for chlorine tonner area. The breathing apparatus shall be kept in the close vicinity of such area. The operators shall be adequately trained for responding to any emergency related to chlorine leak. The hood with connection to scrubbing system shall be provided so that tonner body leaks can be effectively controlled.

• The material handling areas where the tank trucks will be stationed for unloading the inventory into storage tanks shall be segregated depending on the reactivity of the chemicals towards each other. The unloading hose connections shall be accordingly color coded. Necessary safety sign-boards shall be displayed at appropriate locations.

• Necessary ventilation calculations shall be performed for each occupied building in the facility during detailed design stage. The air intake locations of these buildings shall be verified through calculations such as dispersion modelling. Adequate number of gas detectors shall be placed at such air intake locations.

• Dedicated analysis such as electrostatic hazard assessment shall be carried out during detailed design stage to identify the locations prone for generation of static electricity and to suggest suitable measures for ignition control.

Management of Process Safety

• Use of mechanical equipment & tools that easily generate sparks in operation should be prohibited in the areas where flammable inventories such as isopropyl alcohol, carbon Di-sulfide etc. are handled

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9. CONCLUSION

• The cumulative Individual Risk for the onsite population is estimated to be 1.79E-05 per year which falls on the threshold of the ‘Acceptable Region’ and ‘ALARP Region’ as per UK HSE Criteria for Individual Risk (IR). The estimated values for the offsite population are within the ‘Acceptable Region.’

• The societal risk associated with the facility, as shown through F-N Curve, is within ALARP Region. The next section is comprised of set of recommendations suggested to reduce the existing societal risk to possible level.

QRA REPORT FOR PUNJAB REV 1 CHEMICALS & CROP PROTECTION LTD 19/02/2020

APPENDIX 1: FLASH FIRE ENVELOPE

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Figure 7: Flash Fire Envelope for IS1L (METHANOL STORAGE TANK)

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Figure 8: Flash Fire Envelope for IS2L (Di-Methyl Sulfide Storage Tank)

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Figure 9: Flash Fire Envelope for IS2L (O-XYLENE STORAGE TANK)

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Figure 10: Flash Fire Envelope for IS4L (FORMALDEHYDE STORAGE TANK)

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Figure 11: Flash Fire Envelope for IS5L (CARBON DI-SULFIDE STORAGE TANK)

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Figure 12: Flash Fire Envelope for IS6L (ETHANOL STORAGE TANK)

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Figure 13: Flash Fire Envelope for IS7L (ACETIC ANHYDRIDE STORAGE TANK)

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Figure 14: Flash Fire Envelope for IS8L (TOLUENE STORAGE TANK)

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Figure 15: Flash Fire Envelope for IS10L (ISO-PROPYL ALCOHOL STORAGE TANK)

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Figure 16: Flash Fire Envelope for IS11L (ACETIC ACID STORAGE TANK)

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APPENDIX 2: POOL FIRE ENVELOPE

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Figure 17: Pool Fire Envelope for IS1L (METHANOL STORAGE TANK)

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Figure 18: Pool Fire Envelope for IS2L (DI-METHYL SULFIDE STORAGE TANK)

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Figure 19: Pool Fire Envelope for IS3L (O-XYLENE STORAGE TANK)

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Figure 20: Pool Fire Envelope for IS5L (CARBON DI-SULFIDE STORAGE TANK)

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Figure 21: Pool Fire Envelope for IS6L (ETHANOL STORAGE TANK)

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Figure 22: Pool Fire Envelope for IS7L (ACETIC ANHYDRIDE STORAGE TANK)

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Figure 23: Pool Fire Envelope for IS8L (TOLUENE STORAGE TANK)

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Figure 24: Pool Fire Envelope for IS10L (ISO-PROPYL ALCOHOL STORAGE TANK)

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Figure 25: Pool Fire Envelope for IS11L (ACETIC ACID STORAGE TANK)

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APPENDIX 3: TOXIC GAS DISPERSION ENVELOPE

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Figure 26: Toxic Gas Dispersion of CS2 for STEL (12ppm) & IDLH (500ppm) for IS5L (CARBON DI-SULFIDE STORAGE TANK)

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Figure 27: Toxic Gas Dispersion of Chlorine for STEL (3ppm) & IDLH (10ppm) for IS9V (CHLORINE TONNER)

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Figure 28: Toxic Gas Dispersion of HCL for STEL (5ppm) & IDLH (50ppm) for IS12V (FOR HCL STORAGE TANK)

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APPENDIX 4: 3D CONTOURS FOR CONSEQUENCES

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Figure 29: 3D Envelope for Flash Fire for IS1L (METHANOL STORAGE TANK)

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Figure 30: 3D Envelope for Pool Fire for IS1L (METHANOL STORAGE TANK)

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Figure 31: 3D Envelope for Flash Fire for IS2L (DI-METHYL SULFIDE STORAGE TANK)

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Figure 32: 3D Envelope for Pool Fire for IS2L (DI-METHYL SULFIDE STORAGE TANK)

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Figure 33: 3D Envelope for Pool fire for IS3L (O-XYLENE STORAGE TANK)

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Figure 34: 3D Envelope for Flash Fire for IS4L (FORMALDEHYDE STORAGE TANK)

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Figure 35: 3D Envelope for Flash Fire for IS5L (CARBON DI-SULFIDE STORAGE TANK)

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Figure 36: 3D Envelope for Pool Fire for IS5L (CARBON DI-SULFIDE STORAGE TANK)

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Figure 37: 3D Envelope for Flash Fire for IS6L (ETHANOL STORAGE TANK)

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Figure 38: 3D Envelope for Pool Fire for IS6L (ETHANOL STORAGE TANK)

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Figure 39: 3D Envelope for Pool Fire for IS7L (ACETIC ANHYDRIDE STORAGE TANK)

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Figure 40: 3D Envelope for Flash Fire for IS8L (TOLUENE STORAGE TANK)

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Figure 41: 3D Envelope for Pool Fire for IS8L (TOLUENE STORAGE TANK)

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Figure 42: 3D Envelope for Flash Fire for IS10L (ISO-PROPYL ALCOHOL TANK)

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Figure 43: 3D Envelope for Pool Fire for IS10L (ISO-PROPYL ALCOHOL TANK)

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Figure 44: 3D Envelope for Flash Fire for IS11L (ACETIC ACID STORAGE TANK)

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Figure 45: 3D Envelope for Pool Fire for IS11L (ACETIC ACID STORAGE TANK)

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APPENDIX 5: DISASTER MANAGEMENT PLAN

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In order to be in a state of readiness to face any accident or disaster caused by the project operation, a Disaster management plan is required to be prepared. The plan will cover possible disaster, On and Off- site emergency preparedness plans, establishment of emergency Control Centre (ECC), Location of emergency services and duties of officers / staff during emergency.

5A Definitions and Classification of Emergency

An Incident: Undesired event giving rise to death, ill health, injury, damage or other loss.

A Major Incident: Is a sudden, unexpected, unplanned event, resulting from uncontrolled developments during an industrial activity, which causes or has the potential to cause. Serious adverse effects immediate or delayed (death, injuries, poisoning or hospitalization) to a number of people inside the installation and / or to persons outside the establishment, or significant damage to crops, plants or animals or significant contamination of land, water, air or an emergency intervention outside the establishment (e.g. Evacuation of local population stopping of local traffic) or significant change in the process operating conditions, such as stoppage or suspension of normal work in the concerned plant for a significant period of above, or any combination of the above effects.

Emergency: An emergency is an abnormal event, which could result in danger to personnel, property and environment. It could be due to fire, Explosion, Heavy spillage of hazardous liquid, toxic gas release etc.

Major Emergency: Is one that may affect several departments within it and/or may cause serious injuries, loss of life, and extensive damage to property or serious disruption outside the works? It will require the use of outside resources to handle it effectively.

Note: Emergency due to operating conditions, uncontrolled reaction, small fire, small gas leak, spill, failure of power, water, air, steam, cooling media, scrubbing media etc. and which can be locally handled by plant personnel alone (without outside help) is not considered as major emergency.

Disaster: Is a catastrophic situation in which the day-to-day life patterns are, in many instances, suddenly disrupted and people are plunged into helplessness and suffering and as a result need protection, clothing, shelter, medical and social care other necessities of life, such as: Disasters resulting from natural phenomena like earthquakes, volcanic eruptions, storm surges, cyclones, tropical storms, floods, landslides, fierce fires and massive insect infestation. Also in this group, violent drought which will cause a creeping disaster leading to famine, disease and death must be included.

Second group includes disastrous events occasioned by man, or by man's impact on the environment, such as armed conflict, industrial accidents, factory fires, explosions and escape of toxic releases of chemical substances, river pollution, mining or other structural collapses, air, sea, rail and road transport accidents, aircraft crashed, collisions of vehicles carrying inflammable liquids, oil spills at sea and dam failures.

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Hazard: Source or situation with a potential for harm in terms of injury or ill health, damage to property, damage to the workplace environment or a combination of these.

Risk: Combination of the likelihood and consequence(s) of a specified hazardous event occurring

5B Classification of Emergency:

LEVEL – 1 The incident or emergency which are confinable, controllable within the plant premises, which under normal circumstances does not affect area outside the said plant battery limit and controlling does not involve / require external help. This situation is called emergency stand by and affected unit / plant have to handle emergency.

It may be due to

- Small pipe/valve rupture or similar leakages that do not affect outside premises. - Release of toxic chemicals for short duration. - Small fire in the plant. LEVEL – 2

When the incident or emergency is not controlled within 10 to 15 minutes or does not come under control within 10 to 15 minutes, incident controller, site main controller reviews the situation and decides if situation is Worsening.

It may arise due to -

- Leakage of toxic chemicals for long duration. - Medium scale explosion confined to the factory premises. - Medium scale fire inside the factory premises.

LEVEL – 3

After surveying off-site implications of level – 2 emergencies if there is a likely hood of chemical/material gas cloud formation and spreading of cloud in down wind direction affecting neighboring population of industry and villagers and / or in case of following incident IC and SMC are of the opinion that there will be off-site implications.

It may arise due to -

- Heavy / Profuse leakage of toxic / Flammable gases for a long duration. - Explosion of high magnitude affecting the adjacent area. - Major fire inside the factory premises. Note: Level-I and Level- II shall normally be grouped as onsite emergency and Level- III as off- site emergency.

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5C Mode of Emergency:

Man made Natural Calamities Extraneous

• Flood • Riots/Civil Disorder/Mob • Heavy Toxic Leakage/ Spillage • Earthquake Attack • Fire • Cyclone • Terrorism • Explosion • Outbreak of Disease • Sabotage • Failure of Critical Control system • Tsunami • Bomb Threat • Design deficiency • War/Hit by missiles • Unsafe acts • Food Poisoning/Water • In-adequate maintenance Poisoning

On-Site Emergency The On-site emergency plan: deals with, measures to prevent and control emergencies within the factory and not affecting outside public or Environment. Table 1.13: On-Site Emergency Planning Sl. Code of Practice Objective Line of Action No.

1 In Case of Fire at To deal with Fire 1. Any person notices any sign of fire shall Factory/Hazardous efficiently and quickly at start shouting FIRE, FIRE (Aag, Aag) to chemicals storage different locations in the seek assistance and also immediately area/ Diesel and factory including storage take steps to give warning by blowing the Rice husk storage tanks, rice husk storage siren continuously and take steps to area. area and electrical extinguish the fire by using fire Panel. extinguishers available near the site of fire. 2. After giving information reach the spot, remove Man & Machinery and take steps to tackle the fire in accordance with the fire fighting instructions. Inform at security office to get Ambulance if required.

2 In case of Heavy To deal with the 1. Any person who notices any leakage or Spillage, Leakage incidence of hazardous spillage of hazardous chemicals from of hazardous chemicals spillage or storage tank, pipe line or from any chemicals. leakage efficiently and equipment should try to warn the nearby quickly

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persons and report to the shift supervisor without any delay. 2. The Person should not go near the spill unless he is wearing a proper PPE and has been fully trained to handle the chemicals leaks.

Off-Site Emergency The Off-site emergency plan: deals with, measures to prevent and control emergencies affecting public and the environment outside the premises.

Objective • In the effects of the accident or disaster inside the plant is felt outside its premises, it calls for an off- site emergency plan, which would prepared and documented in advance in consultation with the district authorities. • The off-site emergency plan prepared herein will deal with those incidents identified under Level – 3 in the on-site plan, which have the potential to harm persons or the environment outside the boundary of the factory premises. • The most significant risk to outside areas is that associated with a large release flammable and toxic chemicals. Spread of its effected outside the works may require traffic control, evacuation, shelter arrangement. • Off-site emergency plan has been drawn up with a view to mobilize resources and integrate with district contingency plan for an effective system of command and control in combating the emergency. • Thus in brief the two main purpose of the off-site emergency plan are: o To provide the local / district authorities, police, fire brigade, doctors, surrounding industries and the public, the basic information of risk and environment impact assessment and to appraise them of the consequences and the protection prevention measures and control plans and to seek their help to communicate with the public in case of major emergency. o To assist the district authorities for preparing the off-site emergency plan for the district or particulate area and to organize rehearsal from time to time and initial corrective action based on the lesson learnt. Structure of the off-site emergency plan: • This off-site emergency plan will be integrated properly with the district contingency plan to tackle any kind of emergency. The site main controller will keep liaison for this purpose with the district authorities.

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• External telephone facilities from Punjab Chemicals and Crop Protection Ltd. to Local Fire Station, Mutual Aid Members, and Disaster Prevention & Management Centre (DPMC) Punjab will be established for quick communication. • The names of the key persons will be defined to establish contacts and Co-ordinate the activities with the help of the Collectorate and disaster management centre in case of major emergency. • An on-site emergency control room has been identified by Punjab Chemicals and Crop Protection Ltd, which can be activated / used for emergency control and manned round the clock. • As far as off-site emergencies are concerned, information shall be received first by the police control room, DeraBassi on telephone next information to local fire brigade on telephone and to DPMC – SAS Nagar Punjab. The police / fire brigade control room shall in turn inform DSP, collector. • The safety department and individual plant has already the list of quantities of resources like breathing air sets, rescue masks, fire extinguishers, water resources etc. available with various industries in the vicinity which can be spread under Mutual Aid System to tackle such emergencies after receiving call from them. • The District Superintendent of Police, SAS Nagar Punjab District will be in overall charge of security, evacuation and rescue operations at the time of emergency. Arrangement made for off- site emergency • Considering distance from district Head Quarters, other nearby external emergency control organization. Following arrangements will be arranged in consultation with DY. DISH, district Collectorate, mamlatdar. • Disclosure of information to neighbouring organization and population: • Punjab Chemicals and Crop Protection Ltd. will prepare booklet and circulate among neighbouring organization and population containing hazardous operation and chemicals. First aid, emergency treatment, probable types of emergencies that can arise. Preventive steps will be taken to control emergency. Emergency warning siren code system, to make them aware in advance. Punjab Chemicals and Crop Protection Ltd. will carry out group get together, acquaintance round, meeting with neighbouring public, population to train, brief the and make them aware about our operation and preparedness. • The same groups along with external emergency control organization were invited during mock drill, rehearsals for training and acquaintance.

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5D Local crisis group: • As per central government notification and DISH office for preparation of offsite emergency plan and Punjab Chemicals and Crop Protection Ltd. will become member of local level crises group, will set up disaster management centre of industrial area using existing available facility of industries in the area with facility and emergency contact phone numbers. • During emergency with in local group reach in and around industrial area any one can contact DMC – control room situated in both the factories and manned round the clock will initiate actions and arrange to organize resource mobilization and communication. Local crisis group consists of:

Chairman : Dy. Collector

Member Secretary : Asst. Directorate – Industrial Safety & Health

Member : Factory manager of all industries

Member : Transport contractors

Member : Safety Manager, Punjab Chemicals and Crop Protection Ltd.

Member : Police Inspector, Punjab Chemicals and Crop Protection Ltd.

Member : TDO, Punjab Chemicals and Crop Protection Ltd.

Member : Civil defense inspector, Punjab Chemicals and Crop Protection Ltd.

Member : Medical officer, PHC, Punjab Chemicals and Crop Protection Ltd.

Member : Press reporter

Member : Community leader, Sarpanch, nearby village

Member : NGO, Lions club, nearby village

Member : Local social worker, nearby village

• Local crisis group will prepare local emergency response plan and will submit to Directorate – Industrial Safety & Health, SAS Nagar Punjab. • Rehearsal of local off-site emergency response plan will be carried out involving industries nearby as per mutual aid arrangements. • Local crisis group will have to start emergency control action before arrival of and activation of district off site emergency plan and involvement of district crisis group. • Any escalation need of further help will activate full district level off site control room. • All type of emergencies like village fire, chemical accident, natural calamities and industrial accidents will be covered in the scope of local crisis group action plan

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5E District level crisis group: Under chairmanship of collector district level crisis group will be formulated to aim at:

• Update off-site emergency plan regularly • To organize, initiate action for mock drill • To run central control room • To coordinate for training need of all member government officials • To maintain communication link among members through central control room. • To monitor preparation of industrial organization and adequacy of on-site emergency plan. • Dy. Director – Industrial Safety & Health hold responsibility of member secretary for district level crisis group. Communication and warning by Disaster Management Center: • When a disaster occurs, the industry affected by the disaster will immediately inform the disaster management centre with all available information, the DPMC will act as per the contingency plan and DPMC will also communicate immediately to district Collectorate. The integration of on – site plan with district contingency plan and various functions to be carried out are mentioned in chart OFF – SITE emergency plan as follow:

Figure 1.15: Off-Site Emergency Plan

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5F Structure of Emergency Management System Punjab Chemicals and Crop Protection Ltd. shall develop an Emergency Management Team. The management structure shall include the following personnel’s; • Site Main Controllers • Incident Controllers and Deputy Incident Controllers • Key Personnel’s • Essential Workers The other elements of Emergency Plan shall be: • Assembly points • Emergency control center • Fire control arrangements • Medical arrangements • Other arrangements

Figure 1.16: Emergency Organization Chart

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5G Role & Responsibility of Emergency Management Team

Site Main Controller (SMC) Senior most Executives (i.e. Director & Supervisor) of the company shall be nominated as SMC. His task will be to co-ordinate all internal and external activities from the Emergency Control Centre (ECC) at Main Security Gate, from where all operations will be directed. He shall:

• Immediately on being informed of the emergency and its location, will arrive at the site, review the situation and control further actions. • Direct all Emergency Operations within the approved area with the following priorities: Personnel Safety, Plant, Property and Environment Safety and Minimum loss of production. • Co-ordinate to avail services from external agencies like fire brigade, hospitals etc, if called for, following the declaration of major emergency. If necessary, major installations in the vicinity may also be informed of the situation. • Exercise direct operational control of the unaffected section of the plant. • In consultation with the advisory team, expedite the shutting down of loading / unloading operations of tankers and if necessary, instruct the supervisor / security personnel to evacuate tankers. • Ensure that all employees are evacuated from the affected area and the casualties, if any, are given necessary medical attention. Instruct P & A Assistant / Security for rushing casualties to hospitals if required. • Liaise with fire and police officials, pollution control board officials and other statutory bodies and advise them of all possible consequence effects outside the premises. • Arrange for relief of personnel when emergency is prolonged. • Issue authorized statement or press release to the news – media. • Ensure preservation of evidence for enquiries to be conducted by statutory authorities. • Authorize the sounding of “All Clear” and “Evacuation Siren”. • Arrange for obtaining the head – count of all personnel within the premises and cross-checking with the data from records available for no. of persons within the premises. • Nominate a person from advisory team, to maintain chronological log of event during the entire period of emergency.

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Role of Incident Controller (IC) and Deputy Incident Controller (DIC): Respective Shift In-charge of the Plant (Site) & Department holds the responsibility of the Incident Controller, if the incident is in their plant/area. Two Production officers in each shift will be identified as Deputy Incident Controllers.

His primary duties shall be to take charge at the scene of the incident. In the initial stage he may be required to take decisions involving the operation of the other plants or to stop or continue any process and to take technical decisions to control the incident. The deputy incident controller will take the charge of incident controller, if he is not available due to any reason. They will be always available in each shift and can take charge of the incident.

Responsibilities/Duties of Incident Controller and Deputy Incident Controller:

• He shall take charge at the scene of incident. • He shall immediately assess the gravity of risk and alert panel and field operators to start controlling their respective section. • if the emergency is minor, try to prevent by using internal resources like fire extinguishers in case of fire, and cover the spillage by sand in case of liquid spillage. • He will work under the direction of the SMC, but till his arrival he may have to execute following responsibilities. o He will ensure that all the Key Personnel are called. o Direct for evacuation of plant and areas likely to be affected by the emergency. o He shall communicate to the SMC the type of outside help needed. o He shall direct all emergency operations within the affected area with the following priorities. o Personnel safety, including of surrounding community. o Minimum damage to Plant, Property and Environment. o Appropriate actions to minimize loss of Production and Material. o Give information to the head of firefighting and rescue team and other emergency services. o Depending on the incident, instruct partial or total shut down, isolations, depressurization, Nitrogen purging, firefighting and rescue operations. o Instruct upstream/downstream units to take emergency shutdown /cutting off supply and other appropriate actions and emergency evacuation help etc. o Direct for search of casualties. o Evacuate non-essential workers/visitors/contractors to safe assembly points. o Brief site main controller and keep him informed about the developments. o Preserve evidences. This will be necessary for investigation for cause and concluding preventive measures.

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Key Personnel Senior officers of various departments like Fire, Security, Safety, Administration, Engineering, Project, Production, Transport, Pollution control, Technical Services and Stores shall be nominated as Key Personnel in their respective fields. As necessary, they shall decides the actions needed to shutdown plants, evacuate personnel, carryout emergency engineering work, arrange for supplies of equipment’s, utilities, carryout environment monitoring, provide catering facilities, liaise with police, fire brigade and other local authorities, relative of casualties, hospital, press & neighboring industries, action at assembly points, outside shelters and mutual aid center under the direction of the SMC. All the key personnel and other called in so to assist, shall report to the ECC. They shall be available at any time on duty or on call or on holidays.

The responsibilities and duties of key personnel are as follows:

Production Manager • To keep in touch with IC & SMC in assessing/ controlling the emergency. • To guide essential personnel team. • To guide personnel for safe close down of the plant. • To guide transport for safe shifting of materials from one place to other. • To guide mutual aids services and the teams. • To keep informed the SMC about developments. • To make arrangement like emergency light, water etc. • To assess the emergency & evacuate the neighboring factory workers and neighboring population through SMC. • To inform the effect of emergency and steps to be taken to avoid the effects of a radiation etc.

Safety Manager • To assist incident controller in controlling emergency. • To help site main controller in communication. • To provide necessary equipment like FFE (Firefighting Equipments), PPE & RPE. • To guide transport for safe shifting of materials from one place to other. • To guide mutual aids services and the teams. • To keep informed the site main controller about developments. • To make arrangement like emergency light, water etc. • To assess the emergency & evacuate the neighboring factory workers and neighboring population through SMC. • To inform the effect of emergency and steps to be taken to avoid the effects of a Fire etc.

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Security officer • To help incident controller & site main controller at the time of emergency. • To cordon the area and inform incident controller or site main controller about the development of emergency. • To fight the fire with available internal FFE. • To make arrangement for evacuating workers from the place of accident and guide non- essential workers towards company assembly point. • To carry out head counting at assembly point & search of missing persons. • To ensure that the roadway to plant is clear for emergency vehicles. Obtain assistance to keep roadway clear and to stop non-emergency traffic from entering. • To direct their personnel (Response force & Task force) for evacuation of non-essential workers & Crowd control. • To liaise with mutual aid services for their help and guide to them. • To blow emergency siren & all clear siren on receiving message from IC/SMC through telephone office.

Factory Medical Officer • To take charge of Occupational Health Centre. • To provide treatment/ first aid to the affected persons and if necessary, send them to hospitals for further treatment. • To keep liaison with hospitals and inform them about the type of emergency help required as per discussion with Site main control. • Arrangement for adequate stock of antidotes, lifesaving drugs and special medicines. • To keep the record of persons given first aid/ treatment and send them to hospitals with their name. • To keep ready the list of blood groupings. • To inform site main controller about the developing situation. • To guide/instruct first aider, first aid and rescue team in case of any emergency. • To keep ready the list of first aider. • To identify of all the hospitals for facilities to render medical aid to victims of exposure to dangerous chemical substances, burns and other specific injuries. (State authorities, local authorities, ESICS, Private, Railways/Voluntary institutions, trusts etc.) and report to SMC • To keep provisions of buffer stock of essential medicines like intravenous fluids, dressing materials, splints, oxygen cylinders, suction apparatus etc. Keeping in view the large number of third-degree burns, heat radiation.

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General Manager-IR • To assist site main controller and incident controller in controlling emergency. • To guide mutual aids services and the teams. • To keep informed the site main controller about developments. • To make arrangement like emergency light, water, etc. • To arrange external help like Medical, Fire, etc. • To assess the emergency and evacuate the neighboring factory workers and neighboring population through SMC. • To inform the effect of emergency and steps to be taken to avoid the effects of a Fire etc. • To deal with external communication like media and external agencies

Adjacent Plant In-charge • To assist site main controller and incident controller in controlling emergency • To help site main controller in communication. • To guide mutual aids services and the teams. • To keep informed the site main controller about developments.

Telephone Operator He will guide all visitors of admin building to move at assembly point.

Essential Workers (EW) Essential Workers shall be those who shall be trained in Fire Fighting and First Aid. One Supervisor and two helpers from each shift will be identified as EW’s & shall supposed to report at EMERGENCY SITE to take instructions from IC or DyIC. IC/ DyIC work instructions will include:

• To rush at the site for help with fully equipped i.e. firefighting equipment, SCBA sets, etc. • To decide line of action in consultation with incident controller and Key personnel and take appropriate measures to extinguish the fire and to control spillage. • Firefighting and spill control till a Fire Brigade takes the charge. • To help the Fire Brigade and mutual aid teams, if it is required. • Shutting down plant and making it safe. • Emergency engineering work e.g. isolating equipment, material process, providing temporary by- pass lines, safe transfer of materials, urgent repairing or replacement, electrical work, etc. • Provision of emergency power, water, lighting, instruments, Equipments, materials, etc. • Movement of equipment, special vehicle and transport to or from the scene of the accident. • Search, evacuation, rescue and welfare. • The injured will be given First Aid. • To help and assist Factory Medical officer. • Moving tankers or other vehicles from area of risk. • Carrying out atmospheric test and pollution control. 94

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• Manning of assembly points to record the arrival of evacuated personnel. Manning for outside shelters and welfare of evacuated persons there. • Assistance at causalities reception areas to record details of causalities. • Assistance at communication centers to handle outgoing and incoming calls and to act as messengers if necessary. • Manning of works entrances in liaison with the police to direct emergency vehicles entering the work, to control traffic leaving the works and to turn away or make alternative safe arrangements for visitors, contractors and other traffic arriving at the works. • Informing surrounding factories and the public as well as directed by the Site Main Controller. • Any special help required.

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5H Other Elements of DMP

Assembly Point:

In affected and vulnerable plants, all nonessential workers (who are not assigned any emergency duty) will be evacuated from the area and they shall report to specified assembly points. Assembly Points shall be located at a safe place, well away from area of risk and least affected by the down wind direction.

To ensure that workers will not have to approach the affected area to reach the assembly points, proper location and numbers will be marked at assembly points. Each assembly point shall be manned by a nominated person to record the names and dept. At each assembly point, duties of assembly point In- charge will also be displayed in brief. Before reaching an assembly point or subsequently, if it is required to pass through an affected area or due to presence of toxic substances, suitable PPE's including respirators, helmet etc., shall be issued and made available with workers.

Proposed Emergency assembly point is near security gate and near administration block.

Emergency Control Center (ECC):

The Emergency Control Center is the place or room from where the operations to handle the emergency are directed and coordinated. Safe and easily approachable room has been earmarked/identified as the Emergency Control Room.

Telephone and other facilities required with necessary documents shall be displayed in ECC for ready reference. Designated trained personnel will operate ECC. In case of Major Emergency, the Site Main Controller will operate from ECC.

The ECC center will be equipped with the following facilities.

• Internal and external telephone including STD facility • Telephone directory/ Telephone nos. of mutual aid centers • First Aid • Muster roll of workers • Identity card register • Layout plan of the factory showing the location of hazardous materials, assembly point, first aid centers etc. • Map of surrounding area with fire extinguishers location • M.S.D.S • Copy of ON SITE & OFF SITE PLAN • Stationeries like- note book, pen, pencils etc. • S.B. Apparatus • List of Government Agencies /Local press agencies with phone no. • Sand Buckets & Hydrant Network 96

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• Adequate numbers of PPE's Fire Control Arrangements (Fire Fighting, Gas Leak Control and Rescue Operation)

Fire is classified in following three classes. The appropriate fire extinguishers are used to extinguish the different class of fire.

Class A: General Fire - Cotton Waste, Paper, Rubbish and Scrap: water, ABC powder type Class B: liquid Fire - All solvents, Resin, Paints, LDO, HSD: Mechanical foam, ABC type

Class C: Gaseous /Electrical fire - Gaseous fire & panels etc.: CO2, DCP/ABC Sufficient number of fire hydrant valves and riser valves will be arranged to control fire in case of emergency. Apart from this, fire extinguishers will be kept at various locations inside plant and those will be hydrostatically tested and refilled at regular intervals as specified by statutory body.

Fire drill will be carried out periodically for all the security guards apart from safety persons to keep them ready fortnightly. Sufficient amount of firefighting water will always be stored in storage tank for firefighting works. In case of power failure, diesel driven fire engine pump has arranged to generate the power for emergency lighting and to run water pump.

Role of Manager (Fire and Safety)/Shift In-Charge (Fire & Safety)

1. Incident Controller shall direct the firefighting and Emergency operation. His duties include… 2. Keep the constant touch with the SMC/In-charge - EHS. 3. Direct the crew members to the scene of emergency and arrange replenishment of Manpower/ equipment/ extinguishing media etc. Role of EHS Representative:

1. On being notified about the location of fire/ gas leakage, he shall immediately proceeds to the help. 2. Decides his line of action in consultation with Incident controller and takes appropriate measures to handle the emergency. 3. Shall assess the severity of the incident & shall immediately report to emergency controller about the gravity of the situation. 4. He shall also assess the extra requirement required if any, from the neighboring industry.

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Fire crew members

1. On hearing fire alarm & emergency siren, they shall immediately reports to control room and proceed to the scene of emergency and work under the direction of IC/ Dy IC. 2. The personnel availability at the scene of incident shall be made optimize. Emergency Squad Members

1. On hearing Emergency Siren, they shall immediately reports to site main controller, safety in charge or incident controller. 2. They shall combat the emergency situation as per the direction of site main controller, safety in charge or incident controller. 3. They will help for safe evacuation.

Medical Services

The roles of Medical officers are as follows;

1. He will report immediately to the SMC/IC. 2. He will render necessary treatment, at Occupational Health Center. 3. He will arrange for Hospitalization and Treatment at outside hospitals, if required. 4. He will mobilize in getting the services of External medical agencies, other Para –medical services etc. and transportation services etc. 5. He will arrange for extra medical assistance/antidotes, from out, if required. 6. He will arrange for first-aid trained volunteers for necessary help. 7. He will liaise with the Government Health Authorities for treatment of the affected persons nearby. Role of Security In-Charge (Security Officer)

1. On hearing the emergency siren, he shall find out the location of the incident (fire / gas leak / spill / explosion) and inform the location of the same to the key personnel coming to the plant. 2. He will depute the security guards for managing gates and traffic control at the incident site & send remaining guards to the site of incident. 3. He will prevent unauthorized entry in to the site 4. He will render assistance as demanded by the safety in-charge. 5. He will mobilize additional security force for help, if required. 6. He will direct ambulance(s) and emergency vehicle(s) to the scene of incident. 7. He will help evacuate persons within the scene of incident. 8. As directed by the site main controller, he may be required to address the public of surrounding villages for warning / evacuation. Role of Mutual-Aid Members 1. Company will have Mutual Aid with various nearby factories. 2. On receiving the call, they shall proceed immediately with fire squad & fire tenders. 3. They will be guided to the place of the incident by the main gate security guard. 98

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4. The fire squad in-charge will report to the safety in-charge of the unit in which the incident has occurred. Other Arrangements

Other arrangements include external transport (transport center), heavy vehicles, lift/cranes, generator sets to supply emergency power, environment monitoring equipment, special instruments/equipment’s, rescue items etc. shall be made available (if required) from nearby Industries /locations, when available resources do not meet the requirements.

Standard Operating Procedure (Shall Be Followed During Emergency)

1. As soon as emergency alarm is heard, all essential workers shall report to IC or SMC. 2. They shall carefully listen to the instructions given by IC or SMC 3. According to the type of emergency/accident, they shall get equipped with PPE/Firefighting equipment and devices. 4. The runner among the workers shall inform SMC/IC and key personnel if they are not at site. 5. The messenger amongst the workers shall deliver messages to nearby units as per the instructions of SMC/IC. 6. The in-charge of medical arrangements shall prepare first-aid and other required facilities for the injured. 7. The other essential workers shall try to control the emergency as per the instructions given to IC. 8. IC would keep SMC informed about the status of control measures being taken at the site and ask for other requirements eg. Mutual aid, equipment etc. if he find necessary. 9. SMC would co-ordinate with outside agencies regarding control measures being taken, need for external help, evacuation, medical treatment etc. Security system

1. A premise is covered by fully fencing and Main gate is secured by guard for 24 hours. 2. All transport vehicles are checked at the gate for driver licenses, MSDS, Emergency Information Panel and for any unwanted / undesired threat material etc. 3. Security staff takes round throughout the factory for security of plant & others. 4. CCTV camera installed at all critical locations. Communication System

Communication System is a Crucial Factor while handling emergency. Company has quick & effective Communication System through which, any situation, which can lead to emergency, can be informed or known to…

1. All persons working inside the plant. 2. Key Personnel outside during normal working hours & during off-duty hours. 3. Outside emergency services, Statutory and Local Authorities & 4. Neighboring facilities and public leaving in vicinity. 99

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Each and every section, Plant & Department of the Factory will be connected by internal telephones with SMC, Supervisor or IC’s. External Phone at Office and Residence and Mobile shall also be made available with Key Personnel and top executive of the factory. The Communication System shall begin with raising the alarm declaring the emergency, Telephone messages and Procedure to communicate the emergency to other persons & General Public.

Raising the Alarm

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

The alarm sound informs the I.C and the S.M.C that an emergency has been created and emergency organization plan to be activated. The I.C. rushes to the site and shall takes charge of the scene.

Telephone Message

A Telephone operator who is precise, sharp, attentive and quick in receiving and noting the message and subsequently effective in further Communication, shall be appointed. A form to record emergency telephone calls will be available with telephone operator or Person available in Emergency Control Center, who shall record such calls during emergency. Telephonic messages shall be given out by the telephone operator to Site main Controller and key personnel as per the instructions of the Incident Controller. Telephonic messages will also be given to authorities and external agencies to describe the type of emergency. All details of emergency will be collected/ delivered according to this format, available with the telephone operator.

Emergency Time Activities

The probable emergency situation that can arise in the unit and the corresponding control actions as described below shall be followed:

Type of Emergency Whom to Call Directions/ Procedures

Medical Emergencies Factory Security Campus security will assist, contact EMS and direct them to your location. EASC and ENSC technologists are trained in First Aid.

Fire Pull fire alarm (located near the Proceed to the nearest stairwell. main gate) Call nearest fire DO NOT use elevators or brigade. stairwell by elevators. Once outside move away from the exit

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Type of Emergency Whom to Call Directions/ Procedures

and do not reenter unless instructed to do so.

Chemical Spill Factory Security or Plant Environmental Health and Incharge (24 hrs.) Safety will arrange for help with spill cleanup or provide advice on proper clean up procedures as per the operating procedures and MSDS of chemicals.

EMERGENCY SERVICES

S. No. Description Contact Number

1. Avtar Singh (Director) 0172-2581495/ 9872600005

2. Jain Pakash [Sr. V.P. (Works)] 0172-2581495/ 9872600008

3. Ravinder Chadha A.G.M (HR, Admin & Training) 0172-2581495/ 9872600009

4. Laxman Singh (HOD Production) 9876644034

5. Manoj Agnihotri (HOD F&A) 9876081389

6. Vijay Kumar (HOD Engineering) 9872600461

7. Gagandeep Singh (HOD Safety) 8528199009

8. Police Station Lalru 274323

Dera Bassi 280133

9. Fire Station Dera Bassi 283101 & 101

Mohali 2225902

Sec-17, CHD 702333

Sec-32, CHD 600693

10. Ambulance Chandigarh 102

Mohali 102

Lalru 108

11. Hospitals & Dispensaries

a. Dr. Mahesh Batra 702300/ 9814000089

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S. No. Description Contact Number

b. Civil hospital 281010

c. Dr. Chander Hospital 280268

d. Dr. P. C. Swami 280249

e. Dr. Vivekanad 274403

f. ESI Hospital, Mohali 671334

g. General Hospital, Sector 16, Chandigarh 44697, 42756

h. P.G.I Emergency, Chandigarh 541005

i. P.G.I Receiption, Chandigarh 541018

j. S.P. SAS Nagar Punjab (Superintendent of Police) 172 2219211, 172 2219212

❖ Safety Awareness among the workers Details of training and periodic retraining programs for the personnel of safety and fire department

Security guards who act as firemen during fire emergency are trained, retrained and refreshed on regular basis. Safety professional is sent for external training and some training program also conducted at works site by external experts of the field.

Details of Training and retraining programs for the workers

Training programs on safety aspects with special attention to firefighting are regular feature of company. Plant organizes 3-4 sessions every month on safety aspects and cover good number of workmen in these programs.

All these training programs would at least include the following:

• Lectures • Seminars and workshop • Practical Exercises • Distribution and practice safety instructions • Safety quiz contests/competitions for individual as also for groups • Display of safety posters and safety slogans at convenient and conspicuous places. • Explanation of instructions (in the language easily understood by workers) about the possible hazards involved in handling of chemicals ad methods to deal with such hazards failing which possible emergency situation are likely to arise.

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• Developing safety instructions for every job and ensuring practice to these instructions/ booklets or manuals by workers. • Educating workers about the • Physical and health hazards arising out from the exposure of handling substance • Measures taken to ensure safety and control physical and health hazards. • Measures to be taken by workers to ensure safe handling, loading and unloading. • Storage and transportation of hazardous substances • Meaning of various labels and marking used on containers of hazardous substances and to whom to report

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APPENDIX 6: FRAMEWORK FOR MANAGEMENT OF OCCUPATIONAL HEALTH & SAFETY

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Punjab Chemicals and Crop Protection Ltd. will prepare the Occupational Health Surveillance Programme which shall be followed right from the project construction & erection phase and the same shall be updated for the upcoming new facility, if required.

Occupational Health Occupational health needs attention both during construction & erection and operation & maintenance phases. However, the problem varies both in magnitude and variety in the above phases.

Hospital Facilities /Factory Medical Officer & OHC • Company will make formal agreements with nearby hospitals having facilities to attend fire and toxic effect cases, emergency cases, attending the affected persons in the emergency arising out of accidents, if any, etc. • A qualified doctor will be appointed as FMO on retainer ship basis. Apart from him, required medical facilities applicable as per Factories Act shall also be made available. • All types of first aid related accessories, Medicines & Antidotes as prescribed by FMO, etc. shall be made available at conspicuous locations.

Ambulance Van & First Aid Box An Emergency Vehicle shall be made available round the clock to be used as an Ambulance during emergency. First Aid Boxes will be made available at Security gate, emergency room, ETP and process plants. Training will be given to employees for First Aid.

Plan for Periodic Medical Checkup Periodic Medical Examination should be conducted as per the following schedule; Workers employed should be examined by a Qualified Medical Practitioner/ Factory Medical Officer, in the following manner: 1. Before employment, to ascertain physical fitness of the person; 2. During employment, every six months (blood & physical examination) as per Factories Rules, to ascertain physical fitness of the person to do the particular job; Details of Occupational Health Impacts and Safety Hazards

Occupational Hazards Identification Occupational Health Impacts

Exposure to Toxic & Corrosive Chemicals Toxication, Irritation

Exposure to Chemical Dust, Severe irritation to eyes & skin, Respiratory disorder, Fatality, etc. Spillage/ leakage, Overflow

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Slip/trip, fall, electric shock, etc. Body Injury, Burns, Skin sensitization, Fall Injury, Electrocution, Damage to nearby equipment’s, Fatality, etc.

Mitigation measures/ Safety Measures proposed to avoid the human health hazards are mentioned in additional studies. In addition to these safety measures, personal protective equipment (IS approved) will also be provided to the required personnel. List of PPE’s given below.

Table: List of PPE’s

S. No Personal Protective Equipment (PPE’s) Numbers

1. Safety Shoes 350

2. Safety goggles 350

3. Dust masks 350

4. Cartridge Masks 60

5. Hand gloves (Rubber, cotton, etc.) 350

6. Refractive Jacket 30

7. Ear Plugs 350

8. Ear Muffs 350

9. Safety helmet 350

As per 10. Others (PVC apron, SCBA Set, PVC pressure suit) requirement

Details of Work Place Ambient Air Quality Monitoring Plan Work zone monitoring will be carried out by independent competent third party every month. Records will be kept as per Factories Rules. Location for samplings shall be identified. Ambient Air & Noise Monitoring shall be done as per PPCB Consent to operate requirements. Following information will be incorporated in the format for maintaining records of work zone monitoring: • Location/ Operation monitored • Identified contaminant • Sampling instrument used • Number of Samples

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• Range of contaminant concentration as measured in sample. • Average concentration • TWA concentration of contaminant (As given in Second Schedule of Factories Act). • Reference method used for analysis. • Number of workers exposed at the location being monitored. • Signature of the person taking samples. • Other relevant details.

Monitoring of The Occupational Injury & It’s Impact on Workers Following action plan will be prepared & followed to monitor the occupational injury to workers: • Each workplace will be evaluated for the existing work conditions. • Unsafe Act & Unsafe Practices will be identified. • Unsafe equipment’s, unsafe areas, etc. will be identified. • Area will be checked for proper Ventilation and Illumination. • Air-borne concentration of toxic chemicals will be measured and records will be kept. • Evaluation of training & on the job work. Impact of the above mentioned unsafe conditions on workers will be studied and remedial measures for the same will be adopted.

Safety Trainings & Mock Drills Safety trainings (on Safe Material Handling, First Aid, & all Safety Aspects) shall be provided every 15 days by the Safety Officers with the assistance of faculty members called from other Professional Safety Institutions and Universities. In addition to regular employees, limited contractor labors will also be given safety training. To create safety awareness, safety films shall be shown to workers and leaflets shall be distributed.

Mock Drills To evaluate the effectiveness of emergency preparedness and to spread the awareness among employees mock drill will be carried out at the interval of every six months. After completion of the mock drill, summary report shall be made and corrections will be done if any weakness has been observed.

Frequency of Mock Drills On-site emergency: Once every 6 months Off-site emergency: Once every year

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