Expansion & Modernization of Existing Project For Manufacturing of Explosives & Defence Products
7.0 ADDITIONAL STUDIES 7.1 RISK ASSESSMENT 7.1.1 Risk Analysis Accidental risk involves the occurrence or potential occurrence of some accident consisting of an event or sequence of events resulting into fire, explosion or toxic hazards to human health and environment risk assessment (RA) provides a numerical measure of the risk that a particular facility poses to the public. It begins with the identification of probable potential hazardous events at an industry and categorization as per the predetermined criteria. The consequences of major credible events are calculated for different combinations of weather conditions to simulate worst possible scenario. These consequence predictions are combined to provide numerical measures of the risk for the entire facility. MCA stands for maximum credible accident or in other words, an accident with maximum damage distance, which is believed to be probable. MCA analysis does not include quantification of the probability of occurrence of an accident. In practice the selection of accident scenarios for MCA analysis is carried out on the basis of engineering judgement and expertise in the field of risk analysis especially in accident analysis. Detailed study helps in plotting the damage contours on the detailed plot plan in order to assess the magnitude of a particular event. A disastrous situation is the outcome of fire, explosion or toxic hazards in addition to other natural causes that eventually lead to loss of life, property and ecological imbalances. 7.1.1.1 Methodology of MCA Analysis The MCA analysis involves ordering and ranking of various sections in terms of potential vulnerability. The data requirements for MCA analysis are: Operating manual Flow diagram and P& I diagrams Detailed design parameters Physical and chemical properties of all the chemicals Detailed plant layout Detailed area layout Following steps are involved in the MCA analysis: Identification of potential hazardous sections and representative failure cases Visualization of release scenarios considering type and the quantity of the hazardous material Damage distance computations for the released cases at different wind velocities and atmospheric stability classes for heat radiations and pressure waves. Drawing of damage contours on plot plan to show the effect due to the accidental release of chemicals
7.1.2 Identification of Hazards Identification of hazards is an important step in risk assessment as it leads to the generation of accidental scenarios. The merits of including the hazard for further investigation are subsequently determined by its significance, normally using a cut-off or threshold quantity. Once a hazard has been identified, it is necessary to evaluate it in terms of the risk it presents to the employees and the neighbouring community. In principle, both probability and consequences should be considered, but there are occasions where it either the probability or the consequence can shown to be sufficiently low or sufficiently high, decisions can be made on just one factor.
Chapter 7- Additional Studies 7-1
Expansion & Modernization of Existing Project For Manufacturing of Explosives & Defence Products
During the hazard identification component, the following considerations are taken into account. Chemical identities Location of process unit facilities for hazardous materials. The types and design of process units The quantity of material that could be involved in an airborne release and The nature of the hazard (e.g. airborne toxic vapours or mists, fire, explosion, large quantities stored or processed handling conditions) most likely to accompany hazardous materials spills or releases The type and location of likely hazards are summarized below: A. CATEGORY – FIRE PROCESS / STORAGE 1. Plant Surroundings : Jungle Fire
2. Raw Material Storage : Fire in storage area 2.1 Chemicals: Ammonium Nitrate Aluminum powder Acetone Fuse head Storage Sulfur Wax & oil Storage 2.2 Packing Materials: Corrugated boxes store PVC compound Briquette & Coal storage yard
B. CATEGORY – EXPLOSION 1] Magazines 2] Slurry manufacturing plant 3] Emulsion Manufacturing plants 4] Detonating Fuse plant 5] Lead Azide /Lead Styphnate plant 6] ASA Stores 7] ASA Drying 8] Detonators filling & pressing 9] Detonator Crimping House 10] Cast Booster Plant 11] PETN manufacturing 12] PETN Drying 13] Pilot Plant 14] Accessories Testing 15] HMX & Compounded products
C. CATEGORY – TOXIC RELEASE: a. Nitric Acid Storage (CNA & WNA) in PP-8 & PP-10 b. Acetic Acid, Acetic Anhydride & Gama Butyro Lactone in PP-6
7.1.2.1 Hazard Survey This is a formal systematized approach using a rotary form the final rating number provides a relative ranking of the hazard. Inventory analysis and Fire and Explosive Toxicity Index (FEI) are the two techniques employed for hazards identification process.
Chapter 7- Additional Studies 7-2
Expansion & Modernization of Existing Project For Manufacturing of Explosives & Defence Products
i. Inventory Analysis Inventory analysis requires the holdup quantities in process vessels associated, intermediate and main storages. All process materials which are capable of producing major accident hazards owing to their physical and chemical properties are identified. Hold up of materials are calculated on the basis of material balance. Quantities in pipelines are also taken into account. Large or substantial inventories in storage or process streams are indicative of the potential hazards to the plant and its surrounding. Flammability and toxicity factors of these inventories can lead to unpredictable incident. The list of all the holdups is tabulated and the major inventory of chemicals is marked on the plot plan to show the relative significance and interactive effect. Each inventory is evaluated based on its hazards nature, temperature and pressure in relation to the flash point, auto ignition characteristics, MAC value, LD 50 value and its location in the complex. In case of pipeline, the flow rates and the total material handled are also considered since these dynamic inventories may or may not be isolated effectively during accident. The hold up in the system (including pipeline) is quite small as compare to inventories in storage and as such the process holdups are not being considered for hazard analysis. ii. Material Inventory and Storage M/s SIIL maintains adequate inventory of raw material and others utility items (fuels, chemical, solvent etc.) to ensure uninterrupted production of explosives. iii. Inventory and Mode of Storage of Raw Materials The raw material and packaging material details with capacity are given in Table 7.1 and Storage tank details are presented in Table 7.3.
TABLE 7.1 RAW & PACKING MATERIALS Maximum Sr.No Item Description Store location Block UOM Capacity 1 HDPE FILMS S.POWER-80/90 (Domestic) Store-1 KGS 18800 2 HDPE FILMS SUPERCOAL-5 Store-1 KGS 6000 3 SEALING COMPOUND Store-1 KGS 4500 4 HDPE FILMS SOLAR PRIME Store-1 KGS 7500 5 SALT Sodium Chloride STORE-3 Block-1 KGS 58000 6 GUAR GUM (LLVG) STORE-3 Block-2 KGS 20000 7 SODIUM NITRITE. STORE-3 Block-3 KGS 42000 8 PARAFFIN WAX (S.R.)/(F.R) STORE-3 Block 5 KGS 48000 9 SUPER - 1 (MAP) STORE-3 Block-6 KGS 16000 10 SUPER - 2 (DAP) STORE-3 Block-6 KGS 16000 11 EMDILITE DM-45 (For Export) STORE-3 Block 6 KGS 1000 12 MALEIC ANHYDRIDE STORE-3 Block 7 KGS 10000 13 CUPROUS CHLORIDE (C1) STORE-3 Block 7 KGS 250 14 PARA TOLUENE SULFONIC ACID (C2) STORE-3 Block 7 KGS 250 15 S.P.L.-1 (Lauric Acid) STORE-3 Block 7 KGS 3000 16 ALUMINIUM WIRE 1.70 mm (SD) STORE-3 Block 8 KGS 9000 17 G.I.WIRE 1.50 mm (For KP) STORE-3 Block 8 KGS 11000 GLASS BUBBLES (Q-CEL)(PQ 7014) for 18 STORE-3 Block 8 KGS 1860 Domestic Seismic only 19 STRAPPING ROLLS 12 mm (Normal) STORE-3 Block 8 EA 120 20 HOT MELT GLUE (ADHESIVE) STORE-3 Block 8 KGS 1200 21 HDPE FILM SUP.POWER-90, EXPORT STORE-3 Block 9 KGS 9700 22 GLASS BUBBLES (Q-CEL)(PQ 7019)) STORE-3 Block 9 KGS 3000 23 LAYFLATS SOLAR PRIME /GEL STORE-3 Block 10 KGS 8400
Chapter 7- Additional Studies 7-3
Expansion & Modernization of Existing Project For Manufacturing of Explosives & Defence Products
Maximum Sr.No Item Description Store location Block UOM Capacity 24 MAIZE STARCH POWDER STORE-6 Block-4 KGS 36000 25 SEISMIC TUBES STORE-6 B-5-8 NOS 45000 26 COTTON YARN Accessories Stores KGS 24400 27 PAPER BOOSTER SHELLS DO EA 540000 28 PVC REEL EA 14400 29 PVC COMPOUND KGS 50000 30 PENTA ERYTHRITOL ACC STORE KG 48000 31 SODIUM NITRATE (SN) ACC STORE KG 63000 32 DEXTRINE WHITE ACC STORE KG 250 33 DEXTRINE YELLOW ACC STORE KG 250 34 DI PENTA ERYTHRITOL ACC STORE KG 2000 35 SODA ASH KG 60000 36 G.I.WIRE (24.5 Gage) (0.52 mm) C.Box Store KG 20000 37 G.I.WIRE (25.5 Gage) (0.48 mm) C.Box Store KG 40000 38 Sodium Perchlorate STORE-4 KG 178000 39 Sodium Azide DCU-AREA KG 1200 40 Magnesium Oxide DCU-AREA KG 125 41 IPA DCU-AREA KG 2400 42 Lead Sterate DCU-AREA KG 50 43 Lead Nitrate DCU-AREA KG 600 44 MONO ETHYLINE GLYCOL (MEG) PLATFORM KG 11000 45 DEA (DS-302) KG 11000 46 OLEIC ACID (SM-101) KG 9500 47 FURNACE OIL KL 35
TABLE 7.2 STORAGE TANK INSTALLATIONS MATERIAL TANK -1 TANK-2 TANK-3 TANK-4 TANK-5 TANK-6 UNIT LOCATION: MELT ROOM AMMONIUM NITRATE MELT 84 84 - - - - KL CALCIUM NITRATE MELT - 76 57 13.6 13.6 23.5 KL LOCATION: COB/CFB AREA AMMONIUM NITRATE MELT 85 85 85 70 175 - MT CALCIUM NITRATE MELT 15.8 - - - - - FURNACE OIL 40 - - - - - KL SLACK WAX 75 75 - - - - KL LOCATION PETN PLANT ( PP-8/PP-10) CONC. NITRIC ACID (C.N.A) 22 22 22 14 - - KL WEAK NITRIC ACID (WNA) 31 31 31 KL LOCATION HMX PLANT ( PP-6) CONC. NITRIC ACID (C.N.A) 7 - - - - - KL ACTETIC ACID 25 - - - - - KL ACETIC ANHYDRIDE 25 25 - - - - KL DILUTED ACID 20 20 - - - - KL LOCATION HMX PLANT ( PP-15/PP-19) CONC. NITRIC ACID (C.N.A) 20 20 - - - - KL ACETIC ACID 50 50 - - - - KL ACETIC ANHYDRIDE 50 50 - - - - KL DILUTED ACID 50 50 - - - - KL LOCATION TNT PLANT ( PP-18) CONC. NITRIC ACID (C.N.A) 19 19 19 - - - KL ONT 111 111 0 - - - KL OLEUM 43 43 0 - - - KL WEAK NITRIC ACID (WNA) 43 43 0 - - - KL
Chapter 7- Additional Studies 7-4
Expansion & Modernization of Existing Project For Manufacturing of Explosives & Defence Products
MATERIAL TANK -1 TANK-2 TANK-3 TANK-4 TANK-5 TANK-6 UNIT WEAK SULPHURIC ACID (WSA) 75 75 0 - - - KL SPENT ACID 30 30 0 - - - KL CENTRALISE FUEL AREA HEAVY OIL 70 - - - KL PIB 70 70 - - - KL FATTY ACID 70 70 - - - KL SORBITOL 70 - - - KL SMO 70 70 - - - KL PIBSA 12 12 12 10.5 - - KL
7.1.2.2 Identification of hazards area - wise While a detailed study of process materials and buildings have been carried out separately, in order to identify and assess the hazards & risk, it is necessary to produce here a list of principal hazards present in various areas of the factory, for the purpose of on–site emergency planning. 7.1.2.3 On–site emergency planning i. CATEGORY – FIRE On-site emergency situation may arise in case of a massive jungle fire which may threaten to engulf the various explosive installations or flammable material storage facilities inside the factory. The list below enumerates the areas and processes where such fires may initiate. Sr. Material Area PROCESS / STORAGE PETN & HMX plant, SN Plant, LA/LS Mfg., Manufacturing, Usage & 1 Acids Filling & Pressing, Laboratory, ZN plant, COB Testing Raw material, For Storage, Washing & 2 RM Store, Laboratory Solvent, Testing 3 Packing material RM Store & Manufacturing Area For Storage & Packing CFB, SMO,PIBSA , DG6 & FB area of 4 Fuel Blend Manufacturing & Storage Emulsion & Slurry plants Dry Fuel Mixing area, ASA manufacture & 5 Aluminum powder Mixing, storage Stores Manufacturing including 6 Fuse Head Fuse Head Mfg. & Storage dip making, dipping, drying, sorting & Store NC / NC Paint , 7 Fuse Head Mfg. Fuse Head Mfg. Charcoal 8 Sulphur Dry Fuel mixer Sieving, Mixing & Storage Fuse Head Soldering & 9 Lead wires Fuse Head Soldering Curing Acetone, Diesel , Butyl Acetate & 10 Consumable Store, PETN, S- series buildings Storage and Distribution IPA & consumable materials ii. CATEGORY – Explosion On-site emergency situation may happen in case of a major explosion where the sharpnels / debries may fly off to adjoining areas. Only Bazargaon village, which is located about 2 kms east from the factory, could get affected. In west, north or south of the factory is forest land and no residential establishments exist. All the buildings in the plant area have been constructed adhering to the safety norms of the Chief Controller of the explosives. Therefore, there is very low risk of any such emergency situation arising. However, the list below indicates the areas and processes where explosions may occur :
Chapter 7- Additional Studies 7-5
Expansion & Modernization of Existing Project For Manufacturing of Explosives & Defence Products
Sr. Material Area PROCESS / STORAGE PETN/ HMX plants, PETN/ HMX Drying Manufacture, Drying, 1 PETN/ HMX Plants & Store, Filling & Pressing. Cast Storage, Testing, Disposal Booster plants, DF plants, Burning station, Lab by burning, Filling-Pressing Testing, Storage, Drying, 2 LA/LS/ASA Laboratory, Mfg & Storage, Filling & Pressing Manufacturing. Manufacturing plant, Laboratory, Storage Melting, casting, storage. 3 Cast Boosters magazines, cleaning, packing Detonating DF manufacturing plants, Laboratory, Storage Manufacture, Storage, 4 Fuse magazines Testing, Manufacture including Emulsion / Emulsion / Slurry manufacturing plants, mixing, pumping, cartridging 5 Slurry Laboratory, Storage magazines, Trailers & packing , storage, testing, Explosives transportation Filling & Pressing, Crimping, 6 Filled Shell Testing Station, Crimping, Storage Magazines. Magazines. Testing Station, Crimping & Packing, Crimping and Packing, 7 Detonators Magazines. Storage Magazines 8 All Explosives Burning station Disposal by burning
iii. CATEGORY – TOXIC RELEASE Off –site emergency situation may arise if there is a major leak in CNA storage tank or the Glacial Acetic Acid / Acetic Anhydride tank and the fumes are blown away towards population in Bazargaon village prevailing the wind direction towards East or South East. Sr. No. Material Area PROCESS / STORAGE PETN plants ( PP 8 & Manufacture & Storage in case of a 1 Nitric acid Fumes PP10) & HMX plant ( PP 6 leakage / rupture of CNA/WNA tanks. HMX plant ( Acid storage 2 Acetic Acid fumes Manufacturing & Storage. area) Gamma Butyro 3 HMX plant ( PP6) Manufacture & storage Lactone
iv. CATEGORY – Hazard away from site Such situation may arise away from site during transportation of hazardous raw materials from vendors or intermediates from factory to other sites or finished goods from factory to customers. It may be a serious accident on the road or tanker or valve rupture leading to spillage of materials or even explosion of contents. All hazardous chemicals/ products having crossed threshold quantity have been stored with adequate safety measure confirming to PESO/CCOE & MSIHC Rule 1989 compliance and prescribed international standards. 7.1.2.4 Details of plant process The implemented plant process is indigenous and well accepted by other manufactures. M/s. Solar Industries India Limited is manufacturing the various products in separate process houses i.e. Slurry / Emulsion Explosives, Electric Detonators, PETN, Detonating Fuse, Cast Booster, Lead Azide and Lead Styphnate, Detonator filling-pressing, HMX and HMX compounded products. In the manufacturing of Slurry Explosives following process steps are involved. Preparation of Raw Material. Preparation of Mother Liquor Solution.
Chapter 7- Additional Studies 7-6
Expansion & Modernization of Existing Project For Manufacturing of Explosives & Defence Products
Mixing / Blending of Mother Liquor and solid ingredients. Cartridging & Packaging Transfer to Storage Magazines. i. In stores, various raw material listed below are kept separately as per their consumption. The compatibility of chemicals is ensured and licensed chemicals are stored at specific locations. 1. Ammonium Nitrate/ Sodium Nitrate / Calcium Nitrate. 2. Sulphur. 3. Aluminum Powder. 4. Guar Gum. 5. MEG. 6. Corrugated Boxes, Polythene i.e. all packing material. The Raw Materials are weighed in respective store room as per desired quantity. ii. Mother Liquor is prepared by mixing Ammonium Nitrate Melt, Sodium Nitrate and Calcium Nitrate Melt in water and bringing the temperature to 700C by steam heating in reactor. Finally prepared mother liquor is transferred to mother liquor holding tank for final use in process plant PP-2. iii. In Mixing / Blending steps measured quantity of Mother Liquor is pumped into Blender and solid ingredients i.e. Sulphur, Aluminum. Guar gum are added and mixed properly for 10 minutes. iv. After Mixing / Blending of various chemicals, prepared explosives is dumped into hopper. From hopper the material is cartridge in polythene layflats of various diameters. v. The cartridge explosives are packed in corrugated boxes each weighing 25 kg net. The finally packed material is transferred to storage magazine for storage and onward dispatches. A. In the manufacturing of continuous Slurry Explosives following process steps are involved. i. For preparing dry fuel a specified quantity of Starch powder, Sulphur powder and Aluminum flake are mixed in dry condition with Nitrogen purging in the Dry Fuel Mixing (DFM) Area. ii. For preparing the Oxidizer blend (OB) AN /CN melt, are mixed in the reactor. The Gum is mixed with MEG in a separate reactor and added to the OB reactor and transferred to storage tank. iii. Dry Fuel, OB, Cross linker and GA are mixed in the dynamic mixer; prepared matrix is then pumped through roto pump to KP machine for cartridging and packaging. iv. The cartridge explosives are packed in corrugated boxes each weighing 25 kg net. The packed material is transferred to storage magazine for storage and onward dispatches. B. In the manufacture of Emulsion Explosives, the following process steps are involved. Preparation of Raw Material Preparation of Oxidizer Solution. Preparation of Fuel Blend. Preparation of Emulsion Matrix by mixing Oxidizer solution and fuel blend. Addition of do-pants, if necessary. Cartridging is various diameters. Packing and transfer to storage magazine.
Chapter 7- Additional Studies 7-7
Expansion & Modernization of Existing Project For Manufacturing of Explosives & Defence Products
i. Various raw materials like A. N. Melt, Sodium Nitrate, SMO, Waxes, emulsifier etc. are sent to the process plants. ii. Pre weighed quantities AN, SN etc. are charged into a reactor to prepare oxidizer solution. iii. Pre weighed quantities of emulsifiers, oils and waxes are taken into another reactor where a fuel blend is prepared. iv. Desired quantities of oxidizer solution and fuel blend are pumped into a mixer where emulsification and do-pants addition is carried out. v. The emulsion is then pumped into a Cartridging machine and the cartridges sent for packing. C. PETN is manufactured by the nitration of PE (Pentaerythritol) with Conc. Nitric Acid i. Raw materials like PE, Acetone etc are transferred to PETN plants. ii. Required quantity of Conc. Nitric Acid is pumped form storage tanks to nitrator, via a measuring vessel, where the temperature of acid is brought down in the desired limits of process by circulating brine. iii. PE is gradually added to the acid in the nitrator maintaining the desired temperature with continuous stirring. iv. After all PE is added and nitration is completed, the mass of crude PETN is dropped into the acid filter, where the acid is removed by washing with water and subsequently by alkali solution. This PETN is then re granulated with acetone water before final washing. v. There are batch process (PP-8, PP-10) and continuous process manufacture (PP-14) of PETN is used. D. Detonating fuse is manufactured by encapsulating core of PETN in BOPP tape and covering this number of strands of polypropylene yarn & by providing a coating of PVC. i. Raw materials like dry PETN, Polypropylene Yarn, cotton yarn and PVC Granules etc. are transferred to plant. ii. Semi-Fuse is first prepared in a spinning machine by encapsulating a core of PETN in BOPP tape which in turn has yarns for providing covering. iii. Semi-Fuse is then coated with PVC and subsequently passed through crushing rollers. iv. This crushed coated fuse is then wound on reels to the desired length, packed in boxes & sent to magazine. E. Electric Detonators Assembly i. In soldered Fuse Heads and filled shells store, material is unpacked and visually inspected for any defects such as rusting, moisture, improper filling of shells etc. and sent to shop floor. ii. On the shop floor, soldered Fuse Heads are crimped with filled Shells by pneumatic operated collets at high pressure. After crimping, resistance of the lead wire is measured and 25 Nos. crimped Detonators are bundled and sent for packing. iii. Two bundles of 25 each are wrapped in wrapping paper. Such 50 wrapped bundles are packed in fiberboard case. Finally packed fiberboard case is sent to storage magazine for storing & dispatch. F. Cast Boosters are made by first melting TNT in a melting pot and then dispersing PETN in the molten TNT. This molten TNT / PETN mixture is cast into plastic shells and paper shells, packed in CFB case and sent to magazine. G. ASA manufacturing & drying i. Lead Azide (LA) manufacturing measured quantity of lead nitrate solution is taken into the autoclave vessel. The agitator of the autoclave is started with dozing of earlier prepared
Chapter 7- Additional Studies 7-8
Expansion & Modernization of Existing Project For Manufacturing of Explosives & Defence Products
Sodium Azide solution. The resultant Lead Azide is washed with DM water for Minimum 4 time and then the crystal sized are checked before store and used. ii. Lead Styphante (LA) manufacturing measured quantity of Magnesium Styphnate solution is taken into the autoclave vessel The agitator of the autoclave is started with dozing of earlier prepared Lead Nitrate solution. The resultant Lead Styphnate washed with DM water for Minimum 4 time and then the crystal size is checked before storing. iii. ASA drying measured quantity of Lead Azide, Lead Styphnate, Lead Stearate and Aluminum is manually mixed with the help of comb. This mix is termed as ASA and then allowed to get dry in close vicinity with the help coil heater for 1 hour & 30 minutes. The ASA is allowed to cool and collected in conductive bottles (capacity 1 Kg). H. Detonator filling and Pressing i. 104 numbers of empty detonators shells are kept in a ladle made of hylum material. This ladle is then allowed to go through a series of operations in closed vicinity and maintaining the humidity level. ii. In first cubicle a measured quantity of PETN is filled in all the shells and ladle is passed to second cubicle. In second cubicle the filled PETN is pressed by applying pneumatic pressure with the help of SS punches for its proper settling. In the third and fourth cubicle ASA filling and pressing is done respectively. iii. After filling & pressing operation unloading operation is performed to check any loose material and then the filled shells are allowed to rotate in tumbling barrels with saw dust. iv. These filled shells after tumbling are collected and arranged in small cartons in 100 numbers in each carton. 40 numbers of such small cartons with filled shells are then packed in a wooden case. I. HMX & HMX Compounded products HMX is produced by the nitration of Hexamine in Acetic Acid medium by two step Nitration process using a nitrating medium of 85% solution of Ammonium Nitrate in 98% Nitric Acid. The product thus obtained is diluted with water and simmered at 100 deg. C for one hour. This crude HMX is filtered in a vacuum filter and dried in a water oven. It is then crystallized in a solvent and then separated by filtration/Decantation. The HMX is sieved using wet sieving and packed and stored. HMX compounded products such as OCTOL, OKFOL, OMA are manufactured by adding the different additives at the crystallization stage. J. Bulk Emulsion Manufacturing- In the manufacture of Bulk Emulsion Explosives, the following process steps is involved. Preparation of Raw Material Preparation of Oxidizer Solution. Preparation of Fuel Blend. Preparation of Bulk Matrix by mixing Oxidizer solution and fuel blend. i. Various raw materials like A. N. Melt, Furnace oil, SMO, Zinc nitrate etc. are used ii. Pre weighed quantities AN, ZN etc are charged into a reactor to prepare oxidizer solution. iii. Pre weighed quantities of Furnace oils and SMO are taken into another reactor where a fuel blend is prepared. iv. Desired quantities of oxidizer solution and fuel blend are pumped into a Jet mixer where emulsification carried out. v. The Bulk emulsion is then pumped into a hopper and then hopper to silo.
Chapter 7- Additional Studies 7-9
Expansion & Modernization of Existing Project For Manufacturing of Explosives & Defence Products
vi. Finally the bulk emulsion is transferred into BMD vehicle. However up on critical and specific concern area have been identified and detailed hazard mapping and quantum to the extent and damage distance have been enumerated through specific study through CFD modeling. 7.1.3 Disaster Management Plan Objective of DMP is to be in readiness for all mishaps /accidents /fire /injury etc. as the plant is likely to carry out processing with Hazardous chemicals /processing and handling –storage. (Statutory compliance to Factory Act 1948, MSIHC 1989/2002 Rules, CCOE) 1) Emergency procedure 2) Fire organization chart 3) Mock Drill 4) Emergency Center 5) Mutual Aid Member 6) Important Contact Details and Numbrs 7) SOP 8) Hazardous Material Inventory /MSDS 9) Placards/Direction /Do-Don’ts Display at Strategic Location 10) SHE Policy Display 11) Onsite Emergency Plan /Offsite Objective of DMP Disaster management plan of M/s. Solar Industries India limited is prepared to save life, property, plant and machineries and to reduce losses to minimum extent during an accident or disaster. This is also called as disaster management plan. On site emergency plan of M/s. Solar Industries India Ltd. helps to take mitigation actions to staff on duty, nearby people, Fire Brigade, Police, Doctors, Social Organizations during any emergency / disaster. The emergency plan will be circulated to all concerned staff people and offices. It will provide information to them in advance regarding the location of plant, location of hazards inside the plant, assembly points of workers and visitors, location of emergency control center, location and type of safety devices laced, location of control room and power house, exact positions of exit doors at each section, location of fire fighting extinguishers and their type, duties of each personnel working in the factory. This emergency plan is also made to keep total working staff alert with knowledge of facility provided for handling situation during emergency and also their responsibilities, whether they are on duty of not. 7.1.4 Emergency plan This is a plan which answers ‘WHO WILL DO WHAT AND HOW BEFORE, DURING AND AFTER AN EMERGENCY’. 7.1.4.1 Basic Objective of Plan The basic objectives of the plan are to make maximum use of the combined resources of the factory and the outside services to: a) Rescue and treat casualties and safeguard other. b) Initially contain and ultimately bring the accident under control to minimize damage to life, property and the environment. c) Identify the personnel affected/dead, inform their relatives and provide for their needs. d) Ensure safe rehabilitation and resumption of normally in the affected areas.
Chapter 7- Additional Studies 7-10
Expansion & Modernization of Existing Project For Manufacturing of Explosives & Defence Products
e) Provide authorized information to the news media and others. f) Preserve relevant records and evidence for the subsequent enquiry in to the cause and circumstances leading to the emergency. 7.1.4.2 Basic structure The plan has been made in two parts. a) Organizational plan b) Action plan Pre-emergency During emergency and Post emergency 7.1.4.3 Organizational plan This shows the organizational aspect of the plan clearly stating the line of command, each person’s area of responsibilities and organizational setup available for tackling emergencies effectively. 1. Chief Incident Controller The General Manager Works will be the ‘Chief Incident Controller’. As soon as he is informed of the emergency he shall proceed to the ‘Emergency Control Center’. His duties will be: To co-ordinate the rehabilitation activities in the area. To issue authorized statement to the news media.
2. Spot controller Site in charge is the ‘Spot Controller’ and his duties will be: i) Arrange to isolate the area, assess the magnitude of the situation and decide whether all working staff needs to be evacuated to assembly point. ii) Arrange for roll call to check of anybody is missing. iii) Provide guidance to his staff to follow emergency shutdown procedure of the plant. iv) Arrange to activate the hydrant system. v) Arrange for electrical isolation of the area. 3. Communication and Security Co-ordinator The Personal Manager will take charge as the communication and Security Co-coordinator. 7.1.4.4 Action plan i. Pre-Emergency The following actions to be taken in pre-emergency period so that emergency do not take place and if at all an emergency occurs, it could be effectively tackled with minimum possible damages. No. Action Plan Responsibility Sr. G.M. (Tech.) / D.G.M 1. Organize mock drills to Simulate an emergency condition (Safety) Record the deficiencies recorded during the mock drills and take 2. appropriate action to improve the efficacy of the plan in terms of D.G.M. (Safety) our preparedness and response. Ensure that all firefighting equipment are regularly inspected 3. D.G.M. (Safety) and are in proper condition Ensure that scheduled checking 4. D.G.M. (Safety) of all safety devices, interlocks controls, etc. are carried out
Chapter 7- Additional Studies 7-11
Expansion & Modernization of Existing Project For Manufacturing of Explosives & Defence Products
No. Action Plan Responsibility 5. No over licensing of explosives building to be allowed. Site In-charge Regular training program for plant personal on safety, house- Sr. G.M. (Tech.)/Site in- 6. keeping, adherence to operating instruction etc. to be carried charge / D.G.M. (Safety) out. Immediate action to be taken on detection of potential danger or risky situation at all levels. Prompt reporting and timely actions. Sr. G.M. (Tech.)/Site in- 7. charge / D.G.M. (Safety) In situation like sparking, unusual rise in temperature, pressure or sound level, will be required avert a crisis. All the persons of the emergency organization to be trained in 8. the emergency response procedures and use of emergency All Concerned equipment. ii. During emergency A) Emergency Control Center A site emergency control center will be set up in the office block. In case of any emergency, all action relating to tackling of emergency would be co-ordinate and directed from this emergency control center. B) Assembly Point In case of an Emergency all persons are required to assemble in designated Assembly or Evacuation points. Six evacuation points are located as listed below: Assembly Location For the Person of Below plants Point No. Near Security Main Admn. Office, D.G. , PP-1, PP-2, PP-4, PP-5, PP-6, PP-15, 1. Gate ETP, Maintenance work shop, Old burning, Testing & Scrap 2 Near R.M. Store no.-5 PP-3, PP-7, PP-11, PP-12, PP-16, DFM, OB-8 & All Store. Near LA / LS ETP SL-1/2/3, SD-1, DCU-1/2/3/4, DF-1/2, PD-4 Soldering, ETP 3 plant (LA/LS). 4 Near M-10 Magazine- All Magazines, Dispatch office & new burning & Testing. 5 Near CBH-13 PP-8, PP-10, PP14, PD-1/2/3, CBH-1/2/3/4/5 plant & PP 18 Boiler & Thermic fluid boiler, SMO/PIBSA, COB/CFB, STP, AN 6 Near New Colony store, Wire coating, Fabrication work shop & Bulk Plant.
C) Facilities available within the plant to meet an emergency Fire Protection All building area provided with appropriate fire extinguishers. Sand & water buckets have been provided in some buildings. Two internally made Fire tenders with water carrying capacity of 5000 liters each are available inside the factory premises. Supervisors, operators from all buildings and security personnel have been trained in the operation of fire extinguishers. Fire hydrant system is available inside the factory premises with 273 m3/hr water discharge capacity of pump. Discharge points have been provided at critical positions from where fire fighting can be done when required. Supervisors, operators from all buildings and security personnel have been trained in the operation of fire hydrant system. Communication Facilities Internal and external phone are being provided in the emergency control room. At present a wireless system, external phone and a mobile phone are available in the plant premises for communicating to
Chapter 7- Additional Studies 7-12
Expansion & Modernization of Existing Project For Manufacturing of Explosives & Defence Products
senior managers at Nagpur in case of an emergency. An Ambulance is always available at site to transport injured personnel, if required to the hospital. Mutual Aid (Details of outside facilities / agencies available to meet any disaster emergency) In the event of an emergency mutual aid from outside agencies can be sought. Fire Brigade a) Economic Explosives Ltd.: Fire brigade available at our sister company EEL at Sawanga located at 6 km. b) NMC Nagpur: Fire Brigade, Nagpur Municipal Corporation has their own fire tender and well trained crew. Assistance from them could be available on telephone No. 101. c) MIDC, Higna: Fire brigade of MIDC, Hingna, d) OFA: Industrial Estate and Ordinance Factory, Ambajari, Medical Services: a) Primary Health Centre, Kondhali located around 11 kms from the plant and first aid can be provided within half an hour. b) Govt. Medical College: Serious accident cases can be shifted to Govt. Medical College, Nagpur or Mayo Hospital within one hour. c) Dr. Dande Hospital: Industry has an understanding with Dr. Dande Hospital, Ravi Nagar Nagpur to provide medical facility in case of emergency. D) Controller of Explosives: The office of the Chief Controller of Explosives is located at Nagpur. Assistance from their office would be of help in case of an emergency. E) Police Station: Nearest police station is at Kondhali. However, considering the extent of the emergency, more police assistance can be had from Nagpur. Police squad will be very much useful to regulate traffic, shifting of injured personnel to hospital, evacuation of nearby areas, localities etc. Action to be taken during emergency A) By Man at site / supervisor: a. In case Of Fire: b. Raise alarm by shouting ‘Fire Fire’ in order to draw attention of colleagues, passerby. c. Inform security gate and seniors and while reporting give: Your Name: What Happened? Location of Incident: Also indicate whether Emergency action needs to be initiated or not d. Isolate electrical equipment of the plant by operating the emergency switch located outside the building e. Try to remove flammable / dangerous materials lying in the vicinity without endangering yourself. f. Operate fire extinguishers provided in the area. g. In case of fire in a explosive, leave the building immediately raising an alarm , operate the emergency bell and move to nearest evacuation area. h. Inform Security Gate and seniors from nearest telephone available close to the evacuation point and follow reporting guideline as indicated above i. Stay in the evacuation point till instructions are received from seniors.
Chapter 7- Additional Studies 7-13
Expansion & Modernization of Existing Project For Manufacturing of Explosives & Defence Products
j. In case of an Explosion: k. Leave the area raising an alarm and proceed to evacuation point. l. Operate emergency bell and emergency switch to isolate electrical equipment m. Inform seniors from the evacuation area or a safer location giving the location of incident and details of men, equipment involved. Stay in evacuation point till your head count is done and instructions are received from seniors n. In case of toxic release o. Leave the area raising an alarm, Operate emergency bell and proceed to evacuation point taking route upwind of the toxic release. p. Inform seniors from the evacuation area or a safer location giving the location of incident and details of men, equipment involved. Stay in evacuation point till your head count is done and instructions are received from seniors B) Actions by the supervisor / shift in charge / section manager On receipt of information of the emergency from the Man at site, immediately check about the fire or explosion or the toxic release and assess the damage and its potential. Ensure that Security gate and seniors have been informed of the incident. Ensure fire brigade and ambulance services, if required, have been informed and are coming for help. Guide them for quick rescue and fire fighting, if required. Arrange to provide medical aid to injured personnel and if required, send them to hospital. Help security in cordoning of the affected area to ensure no unauthorized persons remain in the affected zone. Provide factual information to Spot controller / seniors and help them in taking control of the situation till they assume charge. With assistance of P&A personnel, arrange to take head count of all persons including visitors and contractors working in the affected area and ensure no one is missed out. C) Action by security personnel at the time of emergency After receiving the Emergency Phone call: Step 1- Ask the details of the calling Person and about incident: Person – 1] Complete name, 2] Plant/Area. Incident – 1] What has happened, 2] Plant/Area, 3] Specific location where the incident occurred in the Plant/Area. Specially check whether Emergency action needs to be initiated or not. Step 2 – Ask for the type of Emergency: Ensure for sending Ambulance Fire Tender or both and send it accordingly on the spot with minimum two guards. Step 3 – Inform to the officials as follows:
Chapter 7- Additional Studies 7-14
Expansion & Modernization of Existing Project For Manufacturing of Explosives & Defence Products
SECURITY OFFICE Intercom No 666/601
1] P.K. MAHTHA 1] M.K.SINGH 1] R.K. SRIVASTAVA 1] Dr. Y.M.PATHODE (Intercom No.529, (Intercom No. 515, (Intercom No.506 (Intercom No. 643 M – 8308353599) *7004 *7002, M-9970156578) M- 9503373994) OR 2] A.N. MATAGHARE M – 9822703942) OR 2]Dr.B.R.KUMBHALKAR 2] R.A. KEDAR (Intercom No. 643) OR (*7021, (Intercom No.650 2] A. PANDE *7010, M-8308445700) M- 9822237998) (Intercom No. 522, 3] A.C. CHOKSE *7015 (Intercom No.649 M – 8888806443) *7013, M- 9403221814) 4] A.A. HARSHE (Intercom No.671 *7011, M-9860886407) 5] Y.K. MISHRA (Intercom No.635 *7025, M-9890067561)
Step 4 – Once Mr. A K Srivastava (Incident controller) reaches the ECC centre: 1] Give him the complete information about the incident (as mentioned in the Step 1 to 3). 2] Assist them in their activity. D) Action by chief incident controller Immediately after he is made aware of the emergency, the Chief Incident Controller will proceed to the Emergency Control Center. Before that he will talk to the spot controller and get the information about emergency. He will inform Chairman and Director about the incident. On arrival to the site he will: - i) Relieve the Spot Controller of responsibilities of overall main control. ii) Declare the type of emergency. If it is fire with explosives, the site will be visited by him along with Spot controller after some time (30 minutes) and based on situation further action would be decided. If it is explosion, the risk of secondary explosion will be considered before entry to the affected site. iii) Inform his subordinates about the incident and outline the course of action that will be taken to mitigate the effects and direct them for specific actions . iv) Exercise direct operational control of those parts of the works outside the affected area. v) Maintain a speculative continuous review of possible developments and assess these to determine most probable cause of event. vi) Direct the shutting down and evacuation of plants where ever required in consultation with the spot controller and key personnel. vii) Arrange for chronological record of the emergency to be maintained. viii) In the case of prolonged emergencies involving risk to outside areas by wind blown material, contact the local Meteorological office to receive early notification of impending changes in weather conditions. ix) Involve himself along with GM (Personnel) in providing information to media & discussions relating to compensation matters. x) Ensure that proper consideration is given to the preservation of evidence.
Chapter 7- Additional Studies 7-15
Expansion & Modernization of Existing Project For Manufacturing of Explosives & Defence Products
E) Action by spot controller: Spot controller: 1. Shift -in-charge or Section Head or 2. AGM Production He will be anyone among the above three who is available in the plant. He will immediately take charge of the emergency situation on receipt of the information and will continue to hold the charge till the physical arrival in the Plant of Chief Incident Controller. Spot Controller will be assisted by shift in charges of Maintenance, Utility & Electrical in emergency actions. Duties of the spot controller: Immediately after he is made aware of the emergency and its location, the Spot Controller will proceed to the emergency site./ Evacuation point. On arrival he will – i) Pending the arrival of the Chief Incident Controller Assume the duties of the post (and in particular) : Direct the shutting down and evacuation of plant and areas likely to be affected. Ensure that the outside emergency services have been called upon. ii) Assess the scale of emergency and decide if a major emergency exists or is likely to occur. On his anticipation he will initiate the major emergency procedure. In case of fire with explosives, approach to the site will be done only after minimum 30 minutes and it will be done by him and Chief incident controller. Based on their assessment further action will be planned. iii) Direct all operations within the affected areas with following priorities. Secure the safety of personnel. Minimize damage to plant, property and the environment. Minimize loss of material. iv) Direct rescue and firefighting or toxic gas control until the arrival of the concerned emergency teams constituted specifically under this plan. v) Ensure that the affected area is combed for preventing further damages. vi) Ensure that all non-essential workers in the affected areas are evacuated to the appropriate assembly point. vii) Report all significant developments to the Chief Incident Controller. viii) Preserve evidence that would facilitate any subsequent inquiry into the causes and circumstances of the emergency. F) Action by security in charge As soon as information is received about the incident, Arrange to cordon off the affected area by security personnel to prevent entry of unauthorized personnel. Make arrangements for crowd control at the factory gate and barrier Liaise with police personnel on their arrival. G) Action by communications & security coordinator On receipt of clearance from Chief incident Controller, He shall immediately operate the communication channel to outside agencies (local police, factory inspector, insurance company, local doctor) and inform about the incident leading to emergency. He shall arrange to transport injured persons to hospital and inform the relatives of injured/ deceased.
Chapter 7- Additional Studies 7-16
Expansion & Modernization of Existing Project For Manufacturing of Explosives & Defence Products
He shall coordinate with CEC for providing information to media and discussions relating to compensations etc. H) Action by S H & E On receipt of information, SH & E Head should Rush to the site to have a firsthand information about the incident & be available to assist CEC Ensure that the incident site is not disturbed until clearance is received from CCE Arrange for photographs of the incident site to be taken Alert the Fire fighters to be ready in case they are required. In case of any fire as a consequence of the incident, arrange for suitable fire-fighting arrangement Liaise with Spot Controller for ensuring safe shut down procedures in the plant, if required. iii. Post emergency Sr. Action Responsibility No. Start of work in the affected area/plant. Work in the affected area can be started only after ensuring that:- all fires, if any are extinguished without the risk of re- 1. Sr. General Manager (Tech.) ignition. - There is no chance of secondary explosion. - Permission, if any required From CCE’s office. Identification of victims and care all victims dead or alive 2. are to be systematically identified and necessary actions P &A Manager taken for medical care and relief etc. Information: 3. Inform CCE by phone followed by letter. Director Do not disturb debris and wreckage except to rescue injured or recover bodies until permitted to do Sr. General Manager (Tech.) so by CCE. Take photographs of wreckage & make suitable Dy General Manager( SHE) sketches of the scene of incident. 4. Inform officer In-charge of nearest police station P &A Manager Inform Factory inspector
5. Inform District Magistrate P &A Manager Committee of Enquiry: Appoint a committee of enquiry to investigation into Director causes of the accident.
Actions of Key Persons in case of Emergency Particulars of Key Persons A. Chief Incident Controller Mr. A. K. Srivastava, Sr. General Manager (Works), Tel. No: External: 07118-277318, Internal: * 7001/ 502 (O) Duties of the chief incident controller As enumerated above in action to be taken during emergency B. Spot controller: As enumerated above in action to be taken during emergency Duties of the spot controller Immediately after he is made aware of the emergency and its location, the Spot Controller will proceed to the emergency site./ Evacuation point. On arrival he will –
Chapter 7- Additional Studies 7-17
Expansion & Modernization of Existing Project For Manufacturing of Explosives & Defence Products
i) Pending the arrival of the Chief Incident Controller Assume the duties of the post (and in particular) : Direct the shutting down and evacuation of plant and areas likely to be affected. Ensure that the outside emergency services have been called upon. ii) Assess the scale of emergency and decide if a major emergency exists or is likely to occur. On his anticipation he will initiate the major emergency procedure. In case of fire with explosives, approach to the site will be done only after minimum 30 minutes and it will be done by him and Chief incident controller. Based on their assessment further action will be planned. iii) Direct all operations within the affected areas with following priorities. Secure the safety of personnel. Minimize damage to plant, property and the environment. Minimize loss of material. Emergency management teams Emergency management teams as under have been constituted and will immediately become functional in case of emergency:- 1) Spot control team 2) Evacuation / Rescue team 3) Maintenance team 4) Fire fighting and safety team 5) Administration team 6) Medical assistance team 7) Transport and traffic control team 1) Spot control team Leader : Mr. R. K. Shrivastava , DGM (Production.) Members : (Person of the Emergency Area will lead with the Spot Controller) 1. Mr. R. A. Kedar, AGM [Production] 2. Mr. A. Chokse, SR. Manager [Production] 3. Mr. A. Harshe, SR. Manager [Production] 4. Mr. Y. K. Mishra, Manager [Production] Shift In-charge, Supervisor from Emulsion & Accessories. Duties: As enumerated above in Action to be taken during Emergency 2) Evacuation / rescue team Leader : Mr. S. Rinayat Dy. Manager (QA) Members : Mr. Ujwal Karalkar. Manager [Project] : Mr. Pankaj Patil Sr. Supervisor (Safety), : Employees of Safety & IT Dept. Duties: i. To report to the Chief Incident Controller and on instruction start rescue measures. ii. To immediately arrange at emergency site, the necessary rescue appliances like rope, shovels, gloves, breathing apparatus, pick axe, hammers, cutting set etc. These emergency appliances have been kept at emergency control center / store.
Chapter 7- Additional Studies 7-18
Expansion & Modernization of Existing Project For Manufacturing of Explosives & Defence Products
iii. To clear the area of unwanted employees to avoid over crowding at the location which otherwise may hamper the emergency operations. iv. To safely rescue the casualties and hand over to the medical care team. v. To keep a count of the casualties rescued. vi. Leader to ensure that the rescue work is done with perfect co-ordination and there is no confusion at any stage. vii. No team member will leave the factory premises unless prior permission is obtained from the leader. 3) Maintenance team Leader Mr. S. Deogaonkar, AGM ( Maint.) Members Mr. R. Kukekar, Manager [Maint.] Mr. Bhavik Jethwa [Electrical.] Electricians, Technicians, Fitters. Duties: i. To cater the maintenance services viz. Water supply, Mechanical, Electrical, Instrumentation and Civil to combat the emergency. ii. The team members will immediately reach to the emergency spot with their emergency kit. iii. They will assist the plant control team to effectively manage the plant under prevailing circumstances by providing maintenance services wherever required. The emergency work may include provision of extra additional lighting, isolating equipment by blinds, making temporary by pass lines etc. iv. The team members will not leave the emergency site without the permission of team leader. 4) Firefighting & safety team Leader: Mr. A.N. Mataghare & A. Bhole ( Assistant Manager-Safety) Mr. R.K. Sharma Sr. Manager (Security) Members: Mr. Rohit Mate (Supervisor- Safety) & Mr. Eknath Adule – (Security Officer & Security Guards). Mr. Narendra / Mr. Kamlesh/ Mr. Ram Das (Fire Tender Drivers) Duties: i. To take stock of the situation and immediately start the fire fighting operations to control the situation arisen due to outbreak of fire. ii. To arrange necessary fire fighting and safety appliances for use by the fire fighting crew and other team members. These emergency appliances are always kept available at emergency control center and include spare fire extinguishers, fireman’s safety suit, breathing apparatus, emergency light, safety helmet, different types of hand gloves, safety belt etc. iii. In fighting the fire, efforts will be made to check spread of fire and then control the fire. Efforts should simultaneously be concentrated to safeguard the maximum possible material from getting involved into the fire by promptly shifting it from the fire place. iv. To maintain the supply of the requisite safety appliances required by other team members. v. The leader will give his advice to the Chief Incident controller to safely combat the situation.
Chapter 7- Additional Studies 7-19
Expansion & Modernization of Existing Project For Manufacturing of Explosives & Defence Products
vi. To ensure that necessary evidence is preserved for the information and examination of statutory authorities. The team members will not leave the emergency site without the permission of team leader. 5) Administration team Leader :Mr. M. K. Singh - G.M.(P& A) Member :Mr. A. Pandey - Manager (P & A) Mr. Santosh Singh (P & A) Mr. Pankaj Singh All Administration & Security employees Duties: i. To immediately close the Main Gate and allow only authorized employees to enter the Plant. ii. To call the outside services like fire brigade, police help, help from neighbor industries etc. iii. To nominate suitable person to take charge of the assembly point to record the names and departments of those reporting there. iv. Everyone available within factory premises should be accounted. v. To summon contractors at assembly point to maintain list of his personnel available in the plant during that emergency and account for them. vi. Visitors already present in the factory at the time of emergency should also be accounted. vii. Depute security guards for controlling traffic at the Main Gate. viii. The deputed security guards on instructions from team leader should open the gate for authorized incoming personnel and vehicles only and inform them about the location of the emergency. ix. Prevent entries or gathering of non-essential persons at the Main Gate. x. Issue authorized statements to the mass media in consultation with Chief Incident controller. xi. To allow visitors and contractor’s personnel to leave with a warning that they should not be the source of unauthorized rumors. (After checking out their names and they sign that they have suffered no physical injury). xii. The team members will not leave without the permission of team leader. 6) Medical assistance Leader - Dr. Kumbhalkar (Medical Officer) Members - Dr. Y. Pathode. (Medical Officer) Mr. Atul Bansod [ Sr. Supervisor-Safety] & All Administration, Safety & Security employees. Duties: i. The team members will report at the first-aid center and await the directions from the leader. ii. The leader will immediately rush the team members to the emergency spot along with the first-aid kits. iii. The leader will keep himself available at the first-aid center and will not leave for the emergency spot. iv. He will avoid crowding of non-essential people at the first-aid center. v. He will immediately press into service the first-aid for the purpose.
Chapter 7- Additional Studies 7-20
Expansion & Modernization of Existing Project For Manufacturing of Explosives & Defence Products
vi. The medical assistance team members may accompany if required the casualties taken outside for treatment. vii. Proper record of the details of persons treated in first-aid center, type of injury, medicines administered, etc will be kept. viii. The team members will not leave without permission of team leader. 7) Transport and traffic control Leader Mr. V. Mate- Manager (Stores) Members Mr. Kamalakar /Ganesh Sahakar (Magazine) Mr. Parminder Singh , Manager(Transport) All employees of Store, Magazine & transport Department. Duties: i. Drivers of all the vehicles will immediately report to the team leader. ii. The team will operate in co-ordination with administration team. iii. The visitor’s vehicle if available at works may be pressed into emergency services with their permission if required. iv. The vehicles movement will be coordinated in such a way that at least one vehicle is available all the time to cater to the emergency. Appointment of other key persons in case of emergency is presented in Table 7.3. TABLE 7.3 OTHER KEY PERSONS IN CASE OF EMERGENCY Team Name Designation / Tel. Specific duties in Department No. Emergency Chief Incident Mr. A. K. Sr. G. M. [Works] 502 Relieve the Spot Controller Controller Shrivastava of responsibilities of overall main control. Coordinator Mr. P.K. Mahtha DGM [Safety] 529 To assist Sr. G.M. [Tech.] /G.M.(Works) Spot Control Mr. R. K. D.G.M. [Prod.] 506 Exercise direct control on Shrivastava Shift In charge 630 the operation for combating Shift In charge emergency Maintenance Mr. S. Deogaonkar AGM [Maint.] 508 Will assume overall control Team of the various maintenance jobs required for the combating the emergency Mr. R. Kukekar Manager [Maint.] 606 Will assist in emergency maint. Jobs Mr. U. Karalkar Manager [Electrical.] 606 Will assist in emergency electrical maint. related jobs Evacuation Mr. S. Rinayat Dy. Manager [QA] 647 Will assume overall charge Rescue Mr. Pankaj Patil Sr. Super. [Safety] 648 of evacuation and rescue operation operation Fire & Safety Mr. Mr. A.N. Assit. Manager 648 Keep overall watch on the Mataghare [Safety] sensitive area. Ensure Mr. R.K. Sharma Sr. Manager 601 initiation of fire fighting Mr. Eknath Adule [security] 602 operation & 666 Security Guard General Mr. M. K. Singh GM [P&A] 515 Responsible for general
Chapter 7- Additional Studies 7-21
Expansion & Modernization of Existing Project For Manufacturing of Explosives & Defence Products
Team Name Designation / Tel. Specific duties in Department No. Emergency Administration admin. & liaison Mr. A. Pande Manager [P & A] 522 As above Transportation Mr. V. Mate 512 & Mr. Kamalakar Manager (store) 677 Responsible for security & Traffic control Mr. Ganesh 656 traffic control Sahakar 657 Mr. Parminder Transport Dept. 658 Singh Mr. Rahul Tewari Medical Dr. Kumbhalkar, 643 He will assume overall Dr. Y Pathode, Company Medical 648 charge of the medical Mr. Atul Bansod Officer assistance to the affected Supervisor & on site and will keep liaison Security Guard - 2 Supervisor [Safety] with medical assistance off Nos (min) site. Facilities available at emergency control center (ECC) A. Communication equipment P & T phones with STD - 6 lines Internal Phones - In each building Wireless Set Mobile Phones Ambulance
B. Vigilance: Site Layout Plan for Factory Layout of process buildings, magazines evacuation area CCTV monitor PPE’s available at plant is given in Table 7.4.
TABLE 7.4 AVAILABILITY OF PPE’S S.No. Name of PPE’s Quantity 1 Fire Suit 1 2 Helmet 6 3 Nose Mask (Cartridge) 2 4 Nose Pad 4 5 PVC Suits 1 6 Hand Gloves (PVC) 3 7 Hand Gloves (Leather) 1 8 Hand Gloves (Asbestos) 2 9 Hand Gloves (Cotton) 3 10 Hand Gloves(Rubber) 1 11 Hand Gloves(Nitrile) 1 12 Safety Goggle 4 13 Safety Belt 1 14 Gumboots 4
Chapter 7- Additional Studies 7-22
Expansion & Modernization of Existing Project For Manufacturing of Explosives & Defence Products
S.No. Name of PPE’s Quantity Artificial Gesticulator {Ambu 15 1 Bag} Stretcher (Kept In 16 1 Ambulance) Emergency Angular Eye 17 3 wash bottle Public Address System 18 1 (Megaphone) 19 Nylon Rope 1 20 Plastic Whistle 2 Self Contained Breathing 21 1 Apparatus ( SCBA)
Actions for specific situations A. ACID STORAGE TANKS : Pre Emergency Plan 1. Periodic checks of acid tanks for corrosion& timely repairs. 2. One of the three storage tanks to be kept empty always. 3. Ensure water ingress to acid storage tanks is avoided. 4. Avoid overfilling of tanks. 5. Keep area free from combustibles. 6. Ensure good condition of electrical fittings. 7. Ensure that fire fighting arrangements are adequate. 8. Ensure that bund is in good working condition. 9. Ensure that bund outlet valve is in working condition. During emergency plan a) In case of Fire - If fire around acid storage tanks is fought with water, take care not to allow water to enter the acid tanks, but keep the tanks cool by spraying water from outside.
Dry chemical/CO2 extinguisher will smother small fires in the immediate neighborhood of the acid tanks. b) In case of major acid leak - Identify source of leak. Isolate and stop leak, if possible. Inform seniors. If threat to life is immediate, the affected area should be abandoned. Warn people in the downwind direction. Stay upwind. Evacuate persons downwind from the source of the leak. If the threat to life is not great and immediate, then the area need simply be cleared and cordoned. Try to contain the acid spillage within the bund.
Chapter 7- Additional Studies 7-23
Expansion & Modernization of Existing Project For Manufacturing of Explosives & Defence Products
Keep the bund outlet valve shut. If possible, try and arrange to transfer contents of affected storage tank to an empty tank. If nitration is in progress, stop it immediately. Do not put water on large leaks. All persons handling acid leaks should do so only after wearing protective clothing and respiratory protection. - For protection of body, hands and feet from the irritating /acidic effects of acid vapour, PVC clothing and gloves should be used. - Compressed air breathing apparatus should be used to provide respiratory, eye & face protection. Keep unnecessary people away. Keep combustibles away (wood, paper, oil etc.) Isolate area until gas has dispersed. Render First Aid, if required. First aid for persons affected by acid a) Contact: Removing acid from contact with body is of primary importance. It is essential to wash and remove any acid that comes in contact with body immediately as delay may result in serious injuries. i) Skin Contact: Get under emergency shower immediately. Remove all contaminated clothing as rapidly as possible while under the shower. If no safety shower is available, flush affected area with large amounts of running water for at least 15 min. Apply DETA (diethyl-tetra-amine) solution liberally on the affected area but with due care not to use force while applying. In case of severe or extensive burns, shock symptoms will often be noticed. In such cases- - put patient on his back - keep him warm but not hot - get medical help
Do not attempt to neutralize the acid with alkali, since the heat of neutralization accentuates the burns. No oil or ointment should be applied unless prescribed by the physician. ii) Eye Contact: Use eye fountain, irrigate the eyes immediately with copious quantities of clean water Hold the eyelids apart to ensure contact of water with all tissues of the eyes and eyelids. If the fountain is not available, pour water over the eyes by holding the eyelids open for at least 15 min. No oil or oily ointment should be used unless prescribed by an eye specialist. b) Inhalation: Remove the victim to an decontaminated area. If the victim is unconscious, check for breathing and for pulse, call for medical help.
Chapter 7- Additional Studies 7-24
Expansion & Modernization of Existing Project For Manufacturing of Explosives & Defence Products
If the victim is conscious, make him lie or sit down quietly. Transfer to hospital as soon as possible. c) Ingestion: If acid has been swallowed and the person is conscious, give him large quantities of water immediately to dilute the acid. Give him milk to drink, if available. Keep patient warm but not hot. Do not attempt to induce vomiting. Do not give anything by mouth to an unconscious victim. Get medical attention immediately. B) AMMONIUM NITRATE Storage Keep area free of combustibles. Ensure area is adequately ventilated. Store in a cool place away from acute fire hazards and on clean floor. Do not stack in piles more than 7 high. Bags of ammonium nitrate should be stored at least 30” away from the walls of the storage building. Leave adequate clearance between the pile and the roof. Store at least 2’away from steam pipe lines, electrical wiring, switches etc. Avoid storage along with organic materials, acids, sulfur, flammable liquids etc. Avoid storage for very long periods. Keep watch on fire sensor alarm, if any signal or alarm sound , act appropriately Emergency contact phone numbers at M/s SIIL is given in Table 7.5 and information flow diagram in case of emergency is presented in Figure 7.1.
TABLE 7.5 EMERGENCY CONTACT PHONE NUMBERS SR.NO. PERSON TO BE CONTACTED PHONE NUMBER SPEED DIAL 1. Main Gate (SECURITY) (O) 601, 602, ___ Mobile- 8308293900 2. Kondhali Police Station (07112) 258134 ----- 3. Kondhali Health Centre (07112) 258164 ----- 4. Fire Brigade Nagpur (EEL/NMC) (EEL) 0718-277363, 722046660 ----- (NMC) 101
5. Govt. Medical College Nagpur (0712) 2764671 ----- 6. Mayo Hospital Nagpur (0712) 2728621/22 ----- 7. Dande Hospital (0712) 2536590
8. Mr. M. S. Nuwal (O) (0712) 2552121 (M) 9890922221 -----
Chapter 7- Additional Studies 7-25
Expansion & Modernization of Existing Project For Manufacturing of Explosives & Defence Products
SR.NO. PERSON TO BE CONTACTED PHONE NUMBER SPEED DIAL 9. Mr. A.K. Jain (O) 0712-2540999 ----- (M) 9822219605 10. Mr. R. K. Guha (O) 527 ® (0712) 2230117 (M) 9823077812 *7028 11. Mr. A. K. Shrivastava (O) 502 ® (0712) 6548670 (M) 9822724936 *7001 12. Mr. M. K. Singh (O) 515 ® (0712) 2584389 (M) 9822703942 *7004 13. Mr. S. S. Mishra (O) 525 (M) 09423106236 *7000 14. Mr. R. K. Shrivastava (O) 505 (M) 9422820491 *7002 (M) 9970156578 15. Mr. P. K. Mahtha (O) 529 *7003 (M) 8308353599 16. Dr. S. K. Sharma (O) 506 (M) 9665081945 *7029 17. Mr. A. Pande (O) 522 (M) 8888806443 *7015 18. Mr. S. S. Deogaonkar (O) 508 (M) 9960445237 *7007 19. Safety Office (O) 648 ___ Mr. M. Dhakate/ Mr. A.N. Mataghare 20. Mr. R. K. Sharma (Security) (O) 601 (M) 8308166400 ----- 21. Dr. B. R. Kumbhalkar (O) 643 *7027 (M) 9822237998 22. Dr. Y. M. Pathode (O) 643 ----- (M) 7507145026
Chapter 7- Additional Studies 7-26
Expansion & Modernization of Existing Project For Manufacturing of Explosives & Defence Products
FIGURE 7.1: INFORMATION FLOW DIAGRAM IN CASE OF EMERGENCY
Location wise list of fire extinguishers is presented in Table 7.6. TABLE 7.6 LOCATION WISE LIST OF FIRE EXTINGUISHERS PLANT TYPE CAPACITY IN KG NOS. TOTAL PP1 DCP 5 Kg 3 4 CO2 4.5 Kg 1 PP-2 DCP 5 Kg 1 3 CO2 4.5 Kg 2 PP-3 DCP 5 Kg 2 3 CO2 4.5 Kg 1 DFM DCP 4 Kg 4 5 CO2 4.5 Kg 1 PP-4 DCP 5 Kg 3 7 CO2 4.5 Kg 4 PP-5 DCP 5 Kg 3 7 CO2 4.5 Kg 4 PP-6 DCP 5 Kg 4 8 CO2 4.5 Kg 3 CO2 2 KG 1
Chapter 7- Additional Studies 7-27
Expansion & Modernization of Existing Project For Manufacturing of Explosives & Defence Products
PLANT TYPE CAPACITY IN KG NOS. TOTAL PP-7 DCP 5 Kg 3 7 CO2 4.5 Kg 4 PP-8 DCP 5 Kg 2 3 CO2 4.5 Kg 1 PP-9 DCP 5 Kg 2 5 CO2 4.5 Kg 3 PP-10 DCP 5 Kg 2 3 CO2 4.5 Kg 1 PP-11 DCP 5 Kg 3 6 CO2 4.5 Kg 3 PP-12 DCP 5 Kg 4 7 CO2 4.5 Kg 3 PP-14 ABC 4Kg 9 13 CO2 4.5Kg 4 PP-16 ABC 4 Kg 4 8 CO2 4.5Kg 4 SN Plant CO2 4.5 Kg 1 1 SMO DCP 5 Kg 3 7 CO2 4.5 Kg 4 PIBSA DCP 5 Kg 4 4 BULK PLANT CO2 4.5 Kg 1 2 DCP 5 Kg 1 MELT ROOM DCP 5 Kg 1 2 CO2 4.5 Kg 1 D S PLANT DCP 5 Kg 1 1 D G ROOM CO2 4.5 Kg 1 2 M/FOAM 9 Lit 1 SUB STATION CO2 9 Kg 1 2 CO2 4.5 Kg 1 OLD ETP CO2 4.5 Kg 1 1 LA/LS ETP ABC 5 Kg 1 1 STP CO2 4.5 Kg 1 1 CBH-1 CO2 4.5 Kg 1 2 DCP 5 Kg 1 CBH-2 CO2 4.5Kg 1 2 DCP 5 Kg 1 CBH-3 ABC 4 Kg 2 3 CO2 4.5 Kg 1 CBH-4 CO2 4.5Kg 2 4 DCP 5Kg 2 PD-1 CO2 4.5Kg 1 2 DCP 5 Kg 1 PD-2 CO2 4.5kg 1 2 DCP 5KG 1 PD-3 DCP 5 Kg 1 2 CO2 4.5 Kg 1 PD-4 CO2 4.5Kg 2 4 DCP 5Kg 2 WDPS DCP 5Kg 1 1 DF-1 CO2 4.5Kg 1 4 DCP 5 Kg 3 DF-2 CO2 4.5 Kg 1 6
Chapter 7- Additional Studies 7-28
Expansion & Modernization of Existing Project For Manufacturing of Explosives & Defence Products
PLANT TYPE CAPACITY IN KG NOS. TOTAL DCP 5Kg 5 DCU-1 CO2 4.5Kg 1 3 DCP 5Kg 2 DCU-2 CO2 4.5Kg 1 3 DCP 5Kg 2 DCU-3 CO2 4.5Kg 2 4 DCP 5Kg 2 DCU-4 CO2 4.5Kg 2 5 DCP 5Kg 3 DIPPING CO2 4.5Kg 3 12 DCP 5Kg 3 ABC 1Kg 6 SOLDERING-1 CO2 4.5Kg 1 3 DCP 5Kg 2 DIPPING CO2 4.5Kg 3 6 DCP 5Kg 3 DCU-FIRE BOOTH CO2 4.5Kg 3 6 DCP 5Kg 3 DCU-Compressor CO2 4.5Kg 1 1 SL-1 CO2 4.5Kg 2 4 DCP 5Kg 2 SL-2 CO2 4.5Kg 3 DCP 5Kg 3 SL-3 CO2 4.5Kg 1 3 DCP 5Kg 2 SD-1 CO2 4.5Kg 1 5 DCP 5Kg 4 LA/LS STORE CO2 4.5Kg 3 DCP 5Kg 3 TDS-1 DCP 5Kg 1 1 TDS-2 DCP 5Kg 1 1 MAIN GATE DCP 5Kg 1 1 MAIN GATE FIRE CO2 4.5Kg 3 6 BOOTH Admin. Office ABC 1 kg 3 7 ABC 2 Kg 2 CO2 4.5 kg 2 ENGG STORE DCP 5 kg 2 2 Store no.6 and C. DCP 5 kg 2 9 Box Store CO2 4.5Kg 3 DCP 5 kg 2 DCP 5 kg 2 STORE NO 5 DCP 5 kg 1 1 STORE NO 3 DCP 5 kg 2 4 FIRST FLOOR DCP 5 kg 1 DCP 2 kg 1 SHED NO 2 CO2 4.5Kg 1 5 DCP 5 kg 4 SHED NO 2 CO2 4.5Kg 1 1 Sulphur Sieving ABC 5 kg 1 1
Chapter 7- Additional Studies 7-29
Expansion & Modernization of Existing Project For Manufacturing of Explosives & Defence Products
PLANT TYPE CAPACITY IN KG NOS. TOTAL Room STORE NO 4 DCP 5 kg 1 1 M-2 DCP 5 kg 1 1 M-7 DCP 5 kg 1 1 M-9 DCP 5 kg 1 1 M-10 DCP 5 kg 1 1 M-11 DCP 5 kg 1 1 M-12 DCP 5 kg 1 1 M-14 DCP 5 kg 1 1 M-15 DCP 5 kg 1 1 M-16 DCP 5 kg 1 1 M-17 DCP 5 kg 1 1 M-18 DCP 5 kg 1 1 M-19 DCP 5 kg 1 1 M-20 DCP 5 kg 1 1 M-21 DCP 5 kg 3 3 M-22 DCP 5 kg 1 1 M-23 DCP 5 kg 1 1 M-24 DCP 5 kg 1 1 M-25 DCP 5 kg 1 1 M-26 DCP 5 kg 1 1 M-27 DCP 5 Kg 4 7 CO2 4.5 kg 3 M-28 DCP 5 kg 1 1 Near M-7 DCP 5 kg 3 6 CO2 4.5 kg 3 Dry PETN Magazine DCP 5 kg 1 1 Garden CO2 4.5 kg 1 1 Main LAB ABC 1 kg 2 2 Record Room ABC 2 Kg 1 1 Old Boiler DCP 5 kg 2 2 Tea Canteen DCP 5 kg 1 1 Welding Room DCP 5 kg 1 1 Wire Coating Plant DCP 5 kg 4 6 CO2 4.5 kg 2 Maint. Workshop CO2 4.5 kg 1 1 Maint. Store CO2 4.5 kg 1 1 Diesel shed M. Foam 9 Lit 1 1 Ammo. Store DCP 5 kg 2 2 Store New DCP 5 kg 3 5 CO2 4.5 kg 2 Godown no.3 CO2 5 kg 1 2 DCP 4.5 kg 1 C. Box Store DCP 5 kg 2 2 Sodium Nitrite DCP 5 kg 1 1 Shed no .2 DCP 5 kg 1 1 Automobile Workshop DCP 5 kg 4 7 CO2 4.5 kg 3 Security Gate no.1 CO2 4.5 kg 2 3 DCP 5 kg 1 Security Gate no.2 DCP 5 kg 4 8 CO2 4.5 kg 4
Chapter 7- Additional Studies 7-30
Expansion & Modernization of Existing Project For Manufacturing of Explosives & Defence Products
PLANT TYPE CAPACITY IN KG NOS. TOTAL New Dispatch Office DCP 4 kg 1 2 CO2 4.5 kg 1 New OB/FB Area DCP 4 kg 1 13 DCP 5 kg 8 CO2 4.5 kg 4 New CFB Area DCP 4 kg 3 3 New SMO DCP 4 kg 2 4 CO2 4.5 kg 2 New PIBSA DCP 5 kg 1 2 CO2 4.5 kg 1 New Boiler ABC 4 kg 1 2 CO2 4.5 kg 1 Stock At Burning DCP 4 kg 6 34 Area DCP 5 kg 11 CO2 4.5 kg 6 M.Foam 9 Lit 1 ABC 1 kg 4 DCP 2 Kg 6 MH-31 AP-776 CO2 2 kg 1 1 MH-31 AP-1176 CO2 2 kg 1 1 MH-31 AP-1311 CO2 2 kg 1 1 MH-31 M-4596 CO2 2 kg 1 1 MH-31 AP-7257 CO2 2 kg 1 1 MH-31 M 4596 CO2 2kg 1 1 CO2 4.5 Kg 3 7 PP-12 ABC 5 Kg 1 DCP 4 Kg 3 PP-5 Container DCP 2Kg 1 1 DF- Container DCP 2Kg 1 1 PP-4 Container DCP 2Kg 1 1 PP-7 zinc oxide DCP 2Kg 1 1 PP-9 DCP 2Kg 1 1 DCU-1 Substation CO2 4.5 Kg 1 1 PP-11 Container ABC 2 Kg 1 1 PP-10 Container DCP 2 Kg 1 1 LAB-Office ABC 1 Kg 1 1
7.2 Off-Site Emergency Planning Once the any mishap or accident so caused if crosses plant boundary and affect outsiders (person, property, environment etc.). In-terms out siders injury /fatality, any other tangential losses then district administration takes control of situation and leads till the normalcy reach out. Administration takes knowledge and information from authorized plant persons. The off-site emergency plan is an integral part of any hazard control system. It is based on those accidents identified by the works management, which could affect people and the environment outside the works. Thus, the off-site plan follows logically from the analysis that took place to provide the basis for the on-site plan and the two plans therefore complement each other. The roles of the various parties that may be involved in the implementation of an off-site plan are described below. The responsibility for the off-site plan will be
Chapter 7- Additional Studies 7-31
Expansion & Modernization of Existing Project For Manufacturing of Explosives & Defence Products
likely to rest either with the works management or with the local authority. During emergency following Table 7.7 shows details with Communication Nos during Offsite Emergency.
TABLE 7.7 COMMUNICATION NOS DURING OFFSITE EMERGENCY Emergency Telephone Nos.
S. No. Authority Telephone No. 0712-2562972, 2564973, 1. Collector, Nagpur 2561755 ® 2 Commissioner ,Nagpur 0712-2532123, 2531756 ® 3 Addl. Commisioner 0712-2561039, 2552214® 4 SDO 0712-2560048 5 Commissioner of Police, Nagpur 0712-2566601, 25650020® 6 Police Control Room 0712-2563333 7 DCP, Traffic Control Room 0712-2706364 0712-2564973,2560543, 8 Disaster Management Plan Mobile 9975386219 9 DGFASLI, Mumbai 022- 24074358,24092203 10 Factory Inspector, Nagpur 0712-2564545, 2551286 11 Fire Brigade NMC, Nagpur 0712-255786, 2783091, 12 Fire Brigade EEL, Sawanga 0718-2777363, 7722046660 13 Chief Controller of Explosives 0712-2510389,2510103, 2510102 14 Civil Surgeon , Nagpur 0712-2774766 15 Police Station , Kondhali 07112-258134 16 MPCB, Nagpur 0712-2560139,2560851 17 Govt. Medical Hospital, Nagpur 0712-2726127, 2725274 18 Govt. Medical Hospital, Nagpur 0712-2749311, 2744671 19 Dande Hospital, Ravi Nagar, Nagpur 0712-2536590, 09890243267 20 Mure Memorial Hospital, Nagpur 0712-2523220 AMBULANCE SERVICES 1 Economic Explosives, Sawanga 7722046660 2 Matruseva Sangh, Nagpur 0712-522393 3 Medical, Nagpur 0712-744671 4 CIIMS, Nagpur 0712-2333381
Either way, the plan must identify an emergency coordinating officer who would take overall command of the off-site activities. Consideration of evacuation may include the following factors: In the case of a major fire but without explosion risk (e.g. an oil storage tank), only houses close to the fire are likely to need evacuation If fire is escalating very fast it is necessary to evacuate people nearby as soon as possible In acute emergency people are advised to stay indoors and shield themselves from the fire. Various Organizations Involved During Emergency Organizational details of command structure, warning systems, implementation procedures, emergency control centers include name and appointments of incident controller, site main controller,
Chapter 7- Additional Studies 7-32
Expansion & Modernization of Existing Project For Manufacturing of Explosives & Defence Products
their deputies and other key personnel involved during emergency. Communications Identification of personnel involved, communication centre, call signs, network, list of telephone numbers. Special Emergency Equipment Details of availability and location of heavy lifting gear, specified fire- fighting equipment, fireboats etc. Voluntary Organizations Details of Voluntary organizations, telephone numbers nearby of hospitals, Emergency helpline, resources etc. are to be available with chief authorities. Medical Aid Local Authority Environmental Health & Safety Department District Level Emergency Committee Plant Level Emergency Committee Hazard works Management Fire Department Emergency Control Center Chief Co –coordinators Police/Traffic Department Public Education EMERGENCY Non-governmental Organizations (NGO) NGO’s could provide a valuable source of expertise and information to support emergency response efforts. Members of NGOs could assist response personnel by performing specified tasks, as planned during the emergency planning process. Evacuation of personnel from the affected area Arrangements at rallying posts and parking yards Rehabilitation of evacuated persons
Chemical information Details of the hazardous substances (MSDS information) and a summary of the risks associated with them have been made available at respective site. Meteorological information There are arrangements for obtaining details of weather conditions prevailing at or before the time of accident and weather forecasts updates. Humanitarian Arrangements Transport, evacuation centres, emergency feeding, treatment of injured, first aid, ambulances, temporary mortuaries. Public Information Dealing with the media-press office Informing relatives, etc. Assessment Collecting information on the causes of the emergency Reviewing the efficiency and effectiveness of all aspects of the emergency plan. Role of local authority Local Authorities- Local authorities like Gram Panchayat, Gram Sabha, municipalities can help in combating emergency situation after assessing the impact scenario in rescue phase.
Chapter 7- Additional Studies 7-33
Expansion & Modernization of Existing Project For Manufacturing of Explosives & Defence Products
Role of Police The police are to assist in controlling of the accident site, Organizing evacuation and removing of any seriously injured people to hospitals. Co-ordination with the transport authorities, civil defence and home guards Co-ordination with army, navy, air force and state fire services Arrange for post mortem of dead bodies. Establish communication centre with easy contact with ECC
Role of Fire Brigade The fire brigade is to be organized to put out fires and provide assistance as required during emergency. Media The media is to have ready and continuous access to designated officials with relevant information, as well as to other sources in order to provide essential and accurate information to public throughout the emergency and to avoid commotion and confusion Efforts are made to check the clarity and reliability of information as it becomes available, and before it is communicated to public Public health authorities are consulted when issuing statements to the media concerning health aspects of chemical accidents Members of the media are to facilitate response efforts by providing means for informing the public with credible information about accidents involving hazardous substances
Role of Health care authorities Hospitals and doctors must be ready to treat all type of injuries to causalities during emergency. Co-ordinate the activities of Primary Health Centre’s and Municipal Dispensaries to ensure required quantities of drugs and equipment Securing assistance of medical and paramedical personnel from nearby hospitals/institutions, Temporary mortuary and identification of dead bodies. 7.3 REHABILITATION & RESETTLEMENT ACTION PLAN The proposed expansion activities will be within the existing plant. Presently 273.910 acres land area is under possession. The total land identified for the proposed project is 2590.44 sqm. The proposed project does not have any displaced persons, due to acquisition of land. There are also no oustees or project affected persons or home oustees, thus R & R plan is not required for this project. However the priority for employment will be given to as per qualification to local persons living in the adjoining villages. In addition to this, promoter will also contribute for the welfare of the people of local surrounding. 7.4 SOCIAL IMPACT ASSESSMENT The local people will be benefited by way of generation of employment opportunities. SIIL is presently employing 1513 persons comprising of various categories such as managers, officers, supervisors and all types of workers and van drivers. The additional manpower requirement for project under revision is 197 persons. Total engagement of manpower in the proposed project will be 1710. All attempts will be made to employ locally available skilled personnel from the study area. In case of
Chapter 7- Additional Studies 7-34
Expansion & Modernization of Existing Project For Manufacturing of Explosives & Defence Products
non-availability of skilled persons, people will be hired from outside the study area. Requirement of un-skilled / semi-skilled people will be mostly met from the local population. The project proponent will provide welfare activities, recreational facilities in the surrounding villages once the plant commences production. The management will conduct regular health checkups in the surrounding villages. There will be enhancement of educational standards of people in the study area. There will be positive and beneficial impacts by way of economic improvements, transportation, aesthetic environment and business generation. There will be an overall upliftment of socio-economic status of people in the area. 7.4.1 Budget For Implementation of Proposed Enterprise Social Commitment (ESC) Solar Industries India Limited (SIIL) has been earmarked 2.5% of the project cost (Rs. 184.01 Crores) for undertaking ESC activities Rs. 4.6 Crores as capital estimate for the ESC activities. The annual recurring expenses for continuing the CSR activities for next 5 years shall be Rs. 4.6 Crores and likewise it will be continued up to the life of the project. ESC activities shall be carried out at Nagpur and surrounding villages of the factory location at Chakdoh and other villages namely Bazargaon, Ringnabodi, Satnavri, Kondhali, Hardoli, Elkapur etc. 7.4.2 Need Based Analysis and CSR Schemes for the study area Need based analysis is defined as a formal process to focus on how a product addresses the needs of community/region. For the need based analysis, primary data collection through structured questioners, direct observations, visits /discussions with local Gram Panchayat Sarpanch/Panchayat members and local peoples was performed in the study area. Sl. Focused Area Observations No. 1. Drinking Water People use hand pumps and well water for potable uses, however water scarcity in summer season reported by villagers, mainly Village Ringnabodi and Satnavri 2. Medical Facilities Study area is semi urban; long distance, lack of access, was seen in the study area. 3. Irrigation facility Farming is the second main occupation of villagers. The villagers have agricultural land but very less access to irrigation facility, due to lack of irrigation facility, dependency on monsoon season agricultural production is very high. 4. Infrastructure Roads were fairly connecting with villages and accessible; however road condition of existing village road was not satisfactory. 5. Drainage System Drainage system was not available in most of the villages of study area. Open drains were seen in the villages with mosquito nuisance. No organized drainage system in the villages was found. 6. Transportation Lack of access for transportation, irregular bus/auto facilities were seen in facility the villages. School/college going students facing problem to attend schools /colleges which were at long distance. Mainly Village Ringnabodi and Satnavri 7. Women Most of the women population was engaged in household activities. empowerment Women literacy was satisfactory in the study area (According to census 2011, out of total workers, only 22% Female population were workers) Women self-help groups were exist in the study area only for money savings purposes. Women literacy was satisfactory in the study area
Chapter 7- Additional Studies 7-35
Expansion & Modernization of Existing Project For Manufacturing of Explosives & Defence Products
TABLE 7.8 BUDGETARY PROVISION FOR IMPLEMENTATION OF PROPOSED ESC ACTIVITIES (IN LAKHS) Sr.no. Particulars Year 1 Year 2 Year 3 Year 4 Year 5 Total 1. Economic Development activities 13 12 11 10 9 55 2. Education facilities 15 14 13 11 10 63 3. Health & Medical facilities 16 13 12 12 11 64 4. Drainage and sanitation facilities 13 12 11 10 9 55 5. Drinking water facilities 15 13 12 9 10 59 6. Infrastructure development 12 12 11 10 10 55 7. Women empowerment 15 13 9 8 8 53 8. Rehabilitation Center 14 12 11 10 9 56 Total 113 101 90 80 76 460
SIIL has already earmarked CSR activities and budgeted and actual expenses are stipulated in the annual balance sheet. TABLE 7.9 BUDGET FOR EARLIER CSR ACTIVITIES (IN CRORES)
Sr. No. Year Budget Amount spent (Crores) 1. 2014-2015 1.76 1.775 2. 2015-2016 2.17 2.23 3. 2016-2017 2.74 2.83 4. 2017-2018 3.00 3.41( up to Jan;2018) M/s SIIL is currently doing CSR activities (Annexure XVI). The company is actively involved in CSR related activities by M/s. SIIL. Budgetary provision has been made from the year 2014-2018 to spend as corporate social responsibilities which are as follows: 1. Contribution for MRI machine at the Central Institute of Medical Science Hospital (CIIMS), Bajaj Nagar, Nagpur Rs. 12 Cr. 2. Contribution towards medical diagnostic equipment’s to various medical institutions / hospitals in Nagpur Rs. 2 Cr. 3. Non Integral Flood light of nearby villages- Rs. 91123/- 4. High Mast Pole 16 M & 12 M - Rs. 400000/- 5. Solar Cookers distribution – Rs. 190000/- 6. Distribution of 450 improved chullahs to reduce dependency on wood fuel /forest 7. Rain water harvesting projects at village Shiva under Rural Infrastructure Development. 8. In view women empowerment training center for sewing established and distribution of sewing machines to entrusted ladies in the vicinity of factory village (2 Lakhs). 9. Infrastructure facilities developed by the company for the welfare of workers, employees and nearby villages with budgetary provisions. 10. SIIL ensuring environmental sustainability through plantation of saplings and annual maintenance of avenue plantation from Bhole Petrol Pump (VIP Road 2 km) to Alankar square. Annual Budget (27 Lakhs). 11. Renovation of class rooms & Making IT enabled, providing sports equipment at Bazargaon.
Chapter 7- Additional Studies 7-36
Expansion & Modernization of Existing Project For Manufacturing of Explosives & Defence Products
12. Paving of playground for students at Middle school Kondhali (1 lakh). 13. Contribution for construction of old age home ”Anandashram” through Aarya Vaishya Nagrik Mandal, Nagpur (2 lakhs). 14. Contribution to ISKCON food relief foundation for mid day meal project to feed 1 lakh school children (11 lakhs). 15. Providing basic life support ambulance, mobile medical van (13 lakhs ) 16. Construction of de addiction center for alcoholic and drug addicts through S M Zade foundation (75 lakhs) SIIL is actively promoting the theme of “Vyasan Mukti Kendra” for rehabilitation of liquor affected person. An NGO is established in 2010 onwards. Financial aid is provided regularly. Refer chapter 10, Table 10.8. 17. Installation of water purifier at Bazargaon and Lok Biradari Prakalp (5 lakhs). 18. Contribution to Police Welfare Fund, Kondhali (10 lakhs). 19. Contribution to Swami Vivekanand Medical Mission (51 lakhs) 20. Contribution to Krishi Vikas Pratishthan (21 lakhs) 21. Contribution to Madhav Netralaya, Nagpur (51 lakhs) 22. Construction of school room at Ringanabodi (10 lakhs) 23. Health Check-up camps (3 lakhs) 24. Contribution to local farmers at Bazargaon (5 lakhs) 25. Donation to Vanrai Foundation for environmental & ecology sustainability(5 lakhs) 26. Construction of R & D Center for medicine from cow waste (50 lakhs) 27. Contribution to Rotary Club for health check-up camps at Bazargaon (2 lakhs). 28. Contribution for Gram Vikas Sanstha (25 lakhs). 29. Contribution to Maharogi Sewa Samiti, Warora for 10 wheels chairs (5 lakhs). Apart from above SIIL providing: 30. Residential quarters to workers. 31. Providing transportation facility to the employees. 32. Providing health cover with Mediclaim policy. 33. Arranging general Health Check-up camp, eye check-up camp, records are maintained. 34. Scholarships to the Employee’s children / allowance for workers. 7.5 BIODIVERSITY CONSERVATION Peacock or Indian peafowl reported within the study area falls under the scheduled-I category. The rest of the fauna reported from the study area, falls under either in schedule-II, Schedule-III or Schedule-IV of the Wild Life Protection Act 1972 and as amended. Few of them like Nilgai and Wild Boar has become threat to the farmers as they are invading their crops very frequently in this region. Hence conservation measures are not provided for these animals. Conservation Measures for Peacock or Indian Peafowl (Pavo cristatus) Schedule – I bird species A Indian peafowl or Peacock or Mor (Pavo cristatus) is a large pheasant justifiably declared as the National Bird of India in 1963 due to its flagship value founded on its glorious position in mythology and its widespread distribution and grandeur. In India, it is given the utmost protection by inclusion in Schedule I of Indian Wildlife Act, 1972. Being a wide spread species, apart from the various urban habitats, it is also found in agriculture fields, along streams with good vegetation and close to human habitations in a semi-feral condition (Johnsgard 1986). In the present study area, these species have
Chapter 7- Additional Studies 7-37
Expansion & Modernization of Existing Project For Manufacturing of Explosives & Defence Products
been confirmed from North –West part of the study area. Their presence confirmed through the extent of vocalization of peacock. Peacock habitats were observed in the area as well as in the vicinity of adjoining agriculture land to forest area. Appearance Male peacock has a spectacular glossy green long tail feathers that may be more than 60 percent of the bird’s total body length. These feathers have blue, golden green and copper colored ocelli (eyes). The long tail feathers are used for mating rituals like courtship displays. The feathers are arched into a magnificent fan shaped form across the back of the bird and almost touching the found on both sides. Females do not have these graceful tail feathers. They have the fan like crest with whitish face and throat, chestnut brown crown and hind neck, metallic green upper breast and mantle, white belly and brown back rump and tail. Their primaries are dark brown. Study Approach Detailed biological survey was carried out for proposed expansion of M/s. Solar Industries India Ltd. located at Village - Chakdoh, Tahsil - Katol, Dist. Nagpur of Maharashtra State. The study area is divided into two parts as core area consisting of project site (273.91 acres.) and the buffer area as the 10 km radius of the project site. Questionnaire survey was also carried out to understand the recent peacock sightings and their movements in the study area. At first, a detailed Primary survey along with consultative approach with villagers was followed to study the wild fauna. Villagers from Ganeshpur, Kundi, Dhaga Garmsur and Murli villages were interviewed randomly. It was observed that, the potential sightings & habitat of peacock was reported by villagers in the study area. Sightings and Habitat Use No peacock was sighted/reported at core zone i.e. project site. However, indirect sightings of the peacock like calls were observed in forest area near villages Ganeshpur, Kundi, Dhaga Garmsur and Murli within study area. The habitat of Peacock observed nearby villages and associated surrounding habitats like agricultural fields and near village water bodies. These species are well adapted to natural village environment conditions. Food and Feeding Habits Peafowls are omnivores, eating plant parts, flower petals, seed heads, insects and other arthropods, reptiles and amphibians. In the study area, dense tree canopy cover supports good insect diversity which is very common food for peafowls. Threats in the Study Area In the study area, no any threat was observed for peacock or its habitats. However, habitat improvement programme is recommended for improvement of population status of this national bird “Peacock”. Habitat Improvement Action Plan Habitat improvement programme will include plantation of various plant species like, Madhuca indica (Maha), Mangifera indica (Amba), Lagerstroemia parviflora (Seja), Tamarindus indica (Chinch), Tectona grandis (Sagaon), Terminalia arjuna (Arjun), Anogeissus laifolia (Dhaora), Anogeissus pendula (Kardhai), Butea monosperma (Palas), Aegle marmelos (Bel) and other species reported from the study area should be taken in to priority. In order to improve vegetation cover, it is suggested to carry out extensive afforestation program. These plant species will help to provide habitat for faunal species, and also increase the species diversity and maintain the naturalness of the surrounding area.
Chapter 7- Additional Studies 7-38
Expansion & Modernization of Existing Project For Manufacturing of Explosives & Defence Products
Seed distribution among the villagers: during this habitat improvement programme the seeds of local fruit bearing trees like Mango, Jamun, Sitafal will be distributed in the various villages of the study area. Compost packets will be also provided at the intervals of the every six months by the proponent (in consultation of forest department). Water feeling in the existing water bodies during summer: Water will be filled in the existing (selected by forest department) water bodies through water tankers. Inference - Buffer Zone as a Peacock Habitat Present survey of the peafowl in the buffer zone of the project site shows that, peafowl is well adapted within the RF as well as fringes of forest of the study area. However, the following points will give an insight on the overall status of peafowl in the study area and thereby plan for better management strategies related to proposed expansion project activities. Local residents of the study area were well aware of the movement pattern of peafowl in their surrounding habitats. Peafowl uses agriculture and various rural habitats as a feeding ground during day time whereas, take shelter on the trees. Core zone do not have potential habitat for roosting or feeding ground for peacock. Moreover, some villages from buffer zone provide roosting and feeding ground for the peafowl, Therefore, it has been visualized that, the proposed expansion project will not have any significant impact on peacock in terms of their normal movements and other activities. However, it is necessity to take some management options like habitat improvement of habitat of peacock in the villages located in the immediate vicinity of the project site. Thus, habitat improvement programme (plantation of recommended and local plant species) will be undertaken in (consultation of forest department) different villages located in the close vicinity of the project area. Under this programme saplings will be distributed in the nearby villages with the consultation of the local forest department. In consultation of the forest department, following Conservation Measures will be adapted for peacock conservation: 1. Habitat improvement programme in the different villages will be undertaken in the buffer zone area for shelter and roosting of peacocks. This will be achieved by plantation of local varieties of the tree species near villages in buffer area. Plantation will also be carried in some forest patches identified by local forest department. 2. School level awareness programmes will be conducted for conservation of peacocks by organizing competitions during “Wildlife Week” and “Van Mahotsav” celebrations. Further Suggestions/recommendations Restricting use of pollutants in their habitat. To carry annual census research projects to ecology and habitat use by peacock. Restricting use of pesticides in agriculture area adjoining to forest areas. By making provision of veterinary care and cages for injured or sick deformed birds. The company has proposed a sum of Rs. 5,00,000/- for the “Peacock” conservation plan up to three years in consultation of local forest department. 1. Plantation- approximately 500 tree/year plants of local plant species for five years. Plants species / verities will be suggested by the local forest department and plant saplings will be distributed in nearby villages for plantation purposes.
Chapter 7- Additional Studies 7-39
Expansion & Modernization of Existing Project For Manufacturing of Explosives & Defence Products
2. Small water hole – 10 in number in 5 villages situated in close vicinity of the Peacock prone area Water hole will be constructed at the area where “Peacocks” generally (nearby habitat). Location of water holes will be suggested by the local forest department in consultation with the Grampanchayt (Sarpanch). 3. Awareness programme for “Peacock” conservation will be scheduled in a year in five Schools every year. During awareness programme following activities will be arranged at the various village level schools as mentioned above (year wise), • “Essay writing on Peacock” • “Drawing competition (Peacock picture) 4. Water Supply and seed distribution Water will be supplied during summer season to the various nearby villages. Water requirement will be cater through tankers in the village ponds or water holes. Seeds of local plant varieties such as Madhuca indica (Maha), Mangifera indica (Amba), Lagerstroemia parviflora (Seja), Tamarindus indica (Chinch), Tectona grandis (Sagaon), Terminalia arjuna (Arjun), Anogeissus laifolia (Dhaora), Anogeissus pendula (Kardhai), Butea monosperma (Palas), Aegle marmelos (Bel), Annona squamosal (Sitaphal), Sygygium cumini (Jabhul), etc. will be distributed above mentioned villages.
Chapter 7- Additional Studies 7-40