66 additional studies€¦ · draft eia report for new dry dock facility at cochin shipyard, kochi,...

Draft EIA Report for New Dry Dock Facility at Cochin Shipyard, Kochi, Kerala

Asian Consulting Engineers Pvt. Ltd. 6-1

1. ADDITIONAL

STUDIES

6.1 RISK ASSESSMENT

6.1.1 Introduction

The risk assessment study is aimed at identifying the potential sources which pose risks of a

hazard outbreak, determining the probability of such hazard occurrences and their

consequences. In doing so, the risk assessment exercise mitigates the severity of any accident

and facilitates preparation of an effective emergency response plan or disaster management

plan. Hazards in a ship building & repair dock are likely to originate from handling & storing

of hazardous substances, dock operations, natural calamities.

6.1.2 Risk Analysis

The most important step is to recognize all the possible hazards and their associated risks in

the site and its surroundings to ensure the safety and consistency of the dock operations. Risk

analysis is the tool used to determine the consequence of operational failure in the dry dock

activities. This will enable the project proponent to design action plan for improving safety

and address the likely outcomes of any incident in the project site.

6.1.3 Hazard Identification

The hazards associated with the construction & operations of the new dry dock facility are

identified as follows:

Chemical Hazard,

Mechanical/ Operational Hazard,

Electrical Hazard,

Fire/ Explosion Hazard,

Hazard from Natural Calamities.

The scenarios linked with the above identified hazards are elaborated in the following sub-

sections.

6.1.3.1 Chemical Hazard

1) During construction:

The CSL will implement the best industry practices in handling and storing the

hazardous chemical, during construction phase, which will include technology

driven safety, monitoring and fault detection measures.

66



Table 6.1: Likely Chemical Hazards in construction of New Dry Dock Area

S.

No.

Hazardous

Material

Storage Hazardous Scenario

1. Paints

(including

anti-fouling)

On-site existing paint

storage room

Breathing problem/ suffocation in

workers exposed to paints in areas

lacking ventilation.

Being highly flammable, surfaces

exposed to paint residues are highly

susceptible to fire.

2. Diesel On site existing

underground storage

tanks

Highly flammable liquid and may

lead to fire in case of leakage, spill.

2) During Operational:

The ship building and repair activities will entail the use of many chemicals (paints)

and gases. Table 6.2 enlists the various chemicals and gases, their handling and likely

hazards. The dry dock operations will implement the best industry practices in

handling and storing the hazardous chemical which will include technology driven

safety, monitoring and fault detection measures. All these facilities will come under

the purview of fire detection and fighting plan as well.

Table 6.2: Likely Chemical Hazards in New Dry Dock Area

S.

No.

Hazardous

Material


3. Paints

(including

anti-fouling)

On-site paint storage

room

Breathing problem/ suffocation in

workers exposed to paints in areas

lacking ventilation.

Being highly flammable, surfaces

exposed to paint residues are highly

susceptible to fire.

4. Carbon

dioxide

New bulk storage in

vertical cylindrical

pressurized vessel

within a secured

compound.

Carbon dioxide is an asphyxiant

and in absence of oxygen will

prove to be fatal.

The storage cylinder may explode

in case of temperature buildup

(>52˚C) around it from incidents

such as fire heat.

5. Acetylene New bulk storage in

cylinders connected

Acetylene is an asphyxiant and in

absence of oxygen will prove to be



S.

No.

Hazardous

Material


to common manifold. fatal.

It is highly flammable and forms an

explosive mixture with air and

oxidizing agent.

Exposure to moderate

concentrations may cause

headache, drowsiness, dizziness,

excitation, excess salivation,

nausea, vomiting, and

unconsciousness.

6. Oxygen Existing liquid

oxygen storage tank.

Oxygen enrichment conditions

highly susceptible to starting fire

and causing fatal burns.

Oxygen enrichment may occur

from:

o Excess use of oxygen in

welding,

o Oxygen leaking from poorly

maintained pipes/ hoses/ valves.

o Oxygen leaking from openpipes/

hoses/ valves.

7. Diesel Highly flammable liquid and may

lead to fire in case of leakage, spill.

6.1.3.2 Mechanical/ Operational Hazard

1) During Construction

Following will be the mechanical/operational hazardous identified during

construction

Collapse of cranes /buildings.

Failure of safety linked control system, detection system, and alarm system.

Occupational hazards originating from slippery surfaces, elevated surfaces, cuts &

bruises, eye injury from welding activities, burns, heat stress, sprains and strains

from manual handling, dust inhalation, machine handling and other ergonomic non-

compliances.

Injury from rope or cable to workers which may even turn fatal.



2) During operational

The mechanical and operation related hazards in the dry dock are like to be from,

Unstable ship during docking and undocking: this may lead to the collision of vessel

with dock structures causing physical damage to the structures involved and

overturning of vessels. Otherwise catastrophic accidents are prevented by following

appropriate procedures.

Flooding of dock: this is critical.

Collapse of cranes /buildings.

Leakage from /failure of dock gates.

During Material handling, such as oil spill on dock, etc.

Failure of safety linked control system, detection system, and alarm system.

Occupational hazards originating from dock flooding, slippery surfaces, trips from

vessels/ elevated surfaces, cuts & bruises, eye injury from welding activities, burns,

heat stress, sprains and strains from manual handling, dust inhalation, machine

handling and other ergonomic non-compliances.

Injury from rope or cable of hauling-in system which may even turn fatal.

6.1.3.3 Electrical Hazard

Electrical hazards are mostly associated with fires caused due to over loading or short-

circuiting phenomena. Fire may originate in switch room, transformer oil store, and high

voltage electricity cables. Unprotected wiring may prove to be fatal if accidentally touched.

6.1.3.4 Fire/ Explosion Hazard

Apart from the many incidents discussed above in being responsible for starting a fire or

explosion, fire may start at any point, at any given time in the presence of the combined

presence of heat, any fuel and oxygen.

6.1.3.5 Hazard from Natural Calamities

Earth Quake

The project is under Zone-III (Moderate risk zone) as per the BMTPC (Building Materials

and Technology Promotion Council), 2006. This will be an important consideration in

designing the dry dock ensuring structural integrity.

Tsunami

Though the study area falls in the shadow zone of the direction of propagation of tsunamis,

unforeseen damages were incurred by the December 2004 tsunami in the coastal stretch

including that of Ernakulam District. Waves of 3 to 5 m height had hit the coast intermittently

leading to loss of lives (about 176 lives) and many injuries (about 1,600 people).



Cyclone and Flood

According to NDMA1, the vulnerability of Ernakulam to flooding is identified as ‘moderate’

and no cyclones have crossed the district till date. However, the coastal Ernakulam region

where the study area falls is regarded as a major flood prone area. The heavy monsoons along

with dense settlements and reclamation activities have been held responsible for the floods.

The project site coast is also vulnerable to monsoon storm surges and sea level rise2. This may

put the lives of the employees and property at stake.

6.1.4 Risk Evaluation

The evaluation of the risks associated with the above identified hazards in the dry dock is

done using the QRA (Qualitative Risk Assessment) method involving the risk matrix. The

qualitative approach is a structured and documented approach in which observations to

several strategic indicative activities are retrieved and the likelihood and consequences

determined based on technical knowhow, professional judgement and experience.

Observations to the following indicative activities are sought (not limited to):

1Cyclone Prone District Report, 2010.

2Kerala State Disaster Management Authority.

Stratification of All Dock Activities

Identification of Hazards against Each Activity

(if any)

Assessing Probability of Occurrence of Identified

Hazards

Gauging Intensity of Consequences if Hazards

Occur

Drawing Mitigation Measures to Act Against

Consequences



The evaluation of risk probability (P) is given a rating of 1 to 5 i.e. rare to almost certain and

the intensity of consequence is rated from 1 to 5 i.e. insignificant to catastrophic. From this

the level of risk or a score is evaluated as,

Risk = Probability (P) x Consequence (C)

The risk score is further classified as unacceptable& to be eliminated, tolerable with

immediate action, acceptable with immediate action. Thus the risk matrix deduced is shown

in Figure 6.1.

Probability

Consequence/ Severity

1 2 3 4 5

Insignificant Minor Moderate Major Catastrophic

5 Almost

Certain

4 Likely

3 Moderate

2 Unlikely

1 Rare

Low Level Risk Moderate Level Risk High Level Risk Extreme Level Risk

Figure 6.1: Risk Matrix

The risk assessment for the hazards identified for the new dry dock operations is detailed out

in Table6.2.

Table6.2: Risk Assessment for New Dry Dock Operations

S.

No.

Hazardous

Activity

Probability

(P)

Consequence

(C)

Risk

Level

Risk Classification

1. Chemical Hazard 2 3 6 Moderate Level Risk:

Tolerable with immediate

action.

2. Mechanical/

Operational

Hazard

4 3 12 High Level Risk:

Unacceptable & to be

eliminated.

3. Electrical Hazard 2 2 4 Low Level Risk: Acceptable

with immediate action.

4. Fire/ Explosion

Hazard 4 4 16

High Level Risk:

Unacceptable & to be

eliminated.

5. Hazard from

Natural

Calamities

1 4 4 Moderate Level Risk:

Tolerable with immediate

action.



6.1.5 Mitigation Measures

For the above risk assessment against each type of hazard, the necessary actions required to

control and/ or eliminate the consequences are discussed in this section. Table 6.3 enlists the

mitigation or control measures against the risks for the new dry dock operations and

construction both.

Table 6.3: Mitigation Measures against Risks for New Dry Dock Operations

S. No. Hazardous

Activity

Risk Level Mitigation/ Control Measure

1) Chemical Hazard Moderate

Level Risk:

Tolerable with

immediate

action.

Regular maintenance of all connections and

monitoring of the same.

Strict supervision of all activities involving the use

of hazardous substances is very important.

Provision for on-site medical facility and first aid

for medical emergencies before further treatment,

like Medical support and ambulance. The project

site is adjacent to the following hospitals:

o V.G. Saraf Memorial Hospital (about 250 m,

East),

o Medical Trust Hospital (about 1 km, North).

Material Safety Data Sheets (MSDS) of all

hazardous substances to be well distributed and

displayed for awareness and knowledge in handling

such substances.

Mandatory use of personal protective equipment

(PPE).

Carbon dioxide Outlets will be located in well ventilated areas.

Acetylene Storage facility to be provided with an automatic

deluge system activated automatically by fire

detection system focused on the active area

(complying with Indian Standards and best practices

of NFPA).

Storage facility structure will be fire resistant and

separated from adjacent operations by a security

fence. Access to be limited to authorized personnel

only.

Facility will be isolated as a Hazardous Area

Classification Zone 1 IEC 679 Part 10-1 (for

internal equipment) for design purposes.



S. No. Hazardous

Activity


Building facility and outlets will be well ventilated.

Ignition sources, vehicle traffic to be restricted from

the areas.

All concerned connections will be handed and

identified to avoid confusion with other gas

connections.

Pipe size will be restricted to prevent accidental

deflagration/detonation.

Pipe wall thickness will be suitable to withstand

mechanical impacts, will have suitable corrosion

allowance.

The storage compound will be placed strategically

at South of the grand assembly area.

Compound will be so placed such that jib crane

lifting activities above the facility are prevented.

Oxygen Storage facility is fire protected and complies with

Indian Standards and best practices of NFPA.

Connections will be handed and identified to evade

any confusion with other connections.

2) Mechanical/

Operational

Hazard

High Level

Risk:

Unacceptable

& to be

eliminated.

All installations will be safely designed, built,

maintained, modified and operated in accordance

with OHSAS 18001 and ISO 14001.

Integrated dock flooding warning system including

public address system to ensure working personnel

are timely alerted before flooding, dewatering

activities.

Remote operations to make sure personnel are at a

safe distance from winches, bollards, capstans while

operating machineries.

Soft stop or variable buffer safeguard options will

be considered to cut down on risks to personnel

from cranes.

Regular monitoring of site and coordinated

supervision is very instrumental in eliminating all

probable risks.

Efficient control and civil teams will be deployed



S. No. Hazardous

Activity


for overall monitoring and coordination through

CCTVs and other technology.

Provision for on-site medical facility and first aid to

aid to medical emergencies before further treatment.

Availability of 24x7 medical officer and ambulance

is a must.

Timely training to all workers and staff in their

specific work areas.

Mandatory use of personal protective

equipment(PPE).

3) Electrical Hazard Low Level

Risk:

Acceptable

with

immediate

action.

Substations will be sealed.

Regular maintenance of the sub-stations, wiring and

monitoring of the same.

Strict supervision of all day-to-day activities is very

important to prevent any untoward incident.

4) Fire/ Explosion

Hazard

High Level

Risk:

Unacceptable

& to be

eliminated.

The comprehensive fire fighting system of the new

dry dock will be very effective in eliminating any

consequential risk.

5) Hazard from

Natural Calamities

Moderate

Level Risk:

Tolerable with

immediate

action.

All installations will be safely designed, built,

maintained, modified and operated in accordance

with OHSAS 18001 and ISO 14001.

Cochin Shipyard Limited has a very proficient emergency action plan in place to ensure

preparedness during the dry dock operations against any emergency situation arising from the

risks identified in the previous section. The emergency action plan is presented below.

6.2 EMERGENCY ACTION PLAN

The emergency action plan of Cochin Shipyard Ltd. i.e. Procedure for Emergency

Preparedness, Issue: A 02(September 2015) is presented below.

6.2.1 Scope

This Emergency Action Plan covers those designated actions of Emergency Response Team

Members that must be taken to ensure employee safety, protection of company installation&

customer safety from Fire and other identified emergencies.



6.2.2 Procedure

a) Identified Emergencies

The emergencies or hazards and their risks are identified.

b) Incident Prevention & Mitigation

A hazard management system will be the basis for ensuring that installations are safely

designed, built, maintained, modified and operated in accordance with OHSAS 18001 and

ISO 14001. As part of this system, hazards and impacts are identified in each process and are

followed by identification of significant risk levels.

Preventive and Mitigation Measures: All the risks and impacts identified will have their own

control measures and will be implemented in the process. This control measures include,

permit to work systems, dock safety inspections etc. This system will be revised based on the

incidents, dock safety inspections and same implemented in accordance with above standards.

Any incident happening out of these control measures requires the following steps to be

followed.

6.2.3 Key Persons

The following key persons are nominated against each post with alternative for each position.

1 Controller Occupier

Alternative Factory Manager

2 Incident Controller Project Manager of the vessel/

Respective Heads of Department /

Officer in charge of the Area.

3 Fire and safety Controller HOD(S&F) / CSO /Sr. SO

4 Personnel& Administrative

Controller

Chief Welfare officer / Welfare officer

5 Communication officer Company Secretary /Asst. Company

Secretary

6 Fire Officer F O / A F O / In charge of fire brigade

7 Security Officer DC(CISF) / Inspector CISF

8 Traffic Control PFSO / Dy. PFSO

9 Service Dept & Sectional Heads Respective Sectional heads

10 Medical Officer CMO/MO

6.2.4 Informing the Emergency

Immediately report all emergencies to Fire / Emergency control room through:

i. Mobile Phone

Or

ii.PABX

Or

iii. Walkie-talkie.



6.2.5 Emergency Action Plan

i. On receiving emergency call, Fire brigade and ambulance will rush to the spot and commence

their action plan.

ii. In-charge of the Fire Team will assess the gravity of the situation and if the situation demands

further assistance, the same will be communicated to Fire Control Room.

iii. Fire Control Room then will annunciate the siren at fire station for alerting the dock.

iv. Fire & Safety Controller shall communicate the mater to Controller and Incident controller

and decision shall be taken for “Declaring Emergency”.

v. On hearing the Siren, all ‘key personnel’ and ‘emergency team members’ shall gather

information on the incident and proceed to incident location.

6.2.6 Duties and Responsibilities

a) Controller

He will be the overall in-charge of the situation and declare a state of Emergency as per

this plan.

On knowing the emergency; immediately proceed to site. A temporary Control room shall

be made functional near incident location.

Discuss with key persons; make decisions for the action plan arrived at. Instruct all

concerned for effective execution of action plan formulated.

Depending on the extent/ nature of emergency, decide on for outside help from nearby

industries and hospitals.

Give instructions for shutdown/ evacuation of dock as per the recommendations of

incident controller.

Ensure that causalities are receiving adequate attention and relatives are informed through

P&A Department.

Ensure that statutory authorities are informed.

Ensure availability of funds to meet the contingency.

Ensure that the Company Directors are informed.

He will issue authorized statements to news media through communication officer.

Declare ‘all clear situation’ once the emergency is over.

b) Incident Controller

He shall report directly to controller.

Immediately on knowing about the emergency, proceed to site.



Quickly assess the scale of emergency and inform controller and finalize action required.

Direct all concerned to act according to the action plan arrived at.

Ensure availability of action team members / power / and all other requirements as per the

action plan.

c) Fire and Safety Controller

On hearing the incident; quickly proceed to the scene and take overall charge of the fire

fighting and rescue operations.

He shall report to Incident controller.

He shall inform the emergency to all key persons as per this plan.

He shall arrange for communicating to action team and direct them to report to incident

controller.

Mobile Control room is mobilized to incident spot.

Arrange additional fire brigades from nearby establishments if required with the direction

of Incident controller.

Establish a danger zone, and coordinate with security officer for proper access control to

affected area.

Report all significant development to the incident controller and controller.

Emergency information documents (2 sets) shall be available at main control room at

incident spot.

Ensure provision of sufficient protective equipment and availability of equipment / tools.

Note: In case of Emergency drill, he shall prepare the Emergency drill incident planand Key

position leaf let and forward to Incident controller before planning the drill. Emergency drill

report shall also be prepared by him.

d) Personnel and administrative controller


When emergency is prolonged, arranging transport vehicles / relief/refreshments to

personnel’s engaged.

Ensure that every one reached the muster point.

e) Communication officer

On the receipt of emergency, proceed to control room and maintain communication under the

guidance of the controller and incident controller.



f) Fire officer

On hearing the incident; he will immediately proceed to the scene, quickly assess situation.

He takes immediate action to control and extinguish the fire with rescue operations if

required. He will supervise the work of the firecrew. Declare Emergency by sounding the

Sound hailer from fire tender after obtaining communication from Fire & Safety Controller.

He will ensure replenishing of fire extinguishing agent and also supervise outside Fire

Brigades if called in. Requirement of outside fire brigade help shall be communicated to

incident controller through Fire &Safety Controller. He shall directly report to Fire & Safety

Controller.

g) Security Officer

He shall report to Incident controller. He will control the gates as per the instructions received

from the traffic controller and arrange for reserved manpower (CISF persons) for supporting

emergency requirements including firefighting and rescue operations.

h) Traffic control

He shall report to Incident controller. He shall direct the security officer tonsure only

authorized personnel and vehicle entry to the factory premises through the entry gates.

i) Service Dept and Sectional Heads


On hearing the incident, the Service Dept heads (U&M, CIV, S&C, and) and sectional

heads under whose control the area/activity where the emergency occurred, will

immediately proceed to the scene of emergency and support the Incident Controller.

Discuss with Incident Controller and action to be finalized.

Actions to be taken to enforce the action plan.

j) Medical Officer


First aid and paramedical services shall be mobilized to the incident spot if required.

He shall send the causalities to the appropriate hospital according the type of injuries and

coordinate with hospitals for the better attention to the causalities and keep a track on it.

k) Action Team

On being alerted of any incident through siren, team members shall report to the incident

controller and action to be executed under the direction of Incident controller.

Immediately mobilize the equipment available in CSL at the incident site as required for

the emergency.



l) Control Room

The Emergency Control room shall contain the following:-

Map of the factory showing entrance, roads, emergency escape gates, assembly point,

medical center, and hazardous zones.

All reference documents.

m) Maintenance and Up Keep of Plan

Planned emergency drill will be conducted once in every six months in the dry dock area.

66 additional studies€¦ · draft eia report for new dry dock facility at cochin shipyard, kochi,...

Documents