“annexure- document of risk...

“Annexure- Document of Risk Assessment”

M/S. ZUARI AGRO CHEMICALS LTD.

EIA & EMP FOR CUSTOMIZED NPK

FERTILIZERS UNIT, GT, HRSG, AAST

& UREA GRANULATION UNIT CH-7: ADDITIONAL STUDIES

KADAM ENVIRONMENTAL CONSULTANTS | SEPTEMBER 2016 194

7 ADDITIONAL STUDIES

7.1 RISK ASSESSMENT

7.1.1 Introduction

ZACL propose to implement a modernization project for revamping of liquid ammonia storage by

replacement of the existing Horton spheres by a double wall type atmospheric pressure storage

tank with superior safety features.

7.1.2 Scope & Methodology

Scope of this Quantitative Risk Assessment (QRA) study of 1X5000 MT capacity is to assess the

risk due to the proposed double wall type atmospheric pressure ammonia tank in place of existing

Horton spheres have capacity of 2X 3000 MT and suggest measures to reduce the risk to levels as

low as reasonably practicable.

This QRA study is carried out using the renowned DNV Phast Risk (also known as Safeti) software

package.

Risk due to a hazard is measured by considering severity level of the consequence as well as

likelihood of its occurrence. The general criteria for risk acceptance are as follows:

Individual risk exceeding 1 x 10(-)4 per year is not tolerable;

Individual risk below 1 x 10(-)6 per year is broadly acceptable;

Individual risk between the above two levels is tolerable if it is demonstrated to be as low as

reasonably practicable (ALARP).

7.1.3 Facility Description

The details of liquid ammonia storage are summarized in Table 7-1.

Table 7-1: Details of Existing and Proposed Liquid Ammonia Tanks

Description No. of Tanks &

Capacity of Each (MT)

Total Capacity

(MT)

Temperature

(C)

Pressure

(kg/cm2g)

Existing

Horton Spheres 2 x 3,000 6,000 5 4

Proposed

Double Wall Type Atmospheric Pressure Tank

1 x 5,000 5,000 (-)33 450- 900 mm WCg

7.1.4 Details of Proposed Atmospheric Pressure Liquid Ammonia Storage

Liquid Ammonia received from road tankers & from Ammonia Plant will be stored in an

Atmospheric Ammonia Storage Tank having a net effective capacity to store 5,000 MT of liquid

Ammonia excluding vapor space. The outer tank is designed for full containment of vapors and

liquid in the event of failure of inner tank.

The tank is equipped with two pressure relief valves to safeguard against overpressure. (Isolation

valves will be provided with suitable mechanical interlock).

The tank shall rest on elevated foundation. Tank pressure is maintained between 450-900 mm

WCg and adequate alarms and interlocks are provided to safeguard the tank against pressure

excursions on either side of the operating range.






Refrigeration System

Liquid Ammonia, at a maximum rate of 90 MT/hr, is received from the tanker unloading line

through a 8” line and at a rate of 45 MT/hr through 6” line from existing Ammonia plant line with

suitable tapping taken at Battery limit (B/L) near the tank. Vapors from flashing and boil off are

withdrawn by two Ammonia Refrigeration Screw Compressors. The gas is compressed and

condensed in water cooled condensers and sent to the Ammonia Receiver.

Liquid is withdrawn from the Receiver under level control. A part of this liquid is flashed in the

Economizer, which operates at a pressure of approximately 1.5 Kg/cm2g. Flashed Ammonia vapors

at about -15°C are admitted into the Economizer port of the Screw Compressors. The balance

liquid Ammonia from the Receiver gets cooled to about – 10°C in the Economizer by the resultant

chill from the above described flashing and is returned back to the storage tank.

Transfer of Liquid Ammonia

Liquid ammonia from tank will be transferred at the rate of 46 m3/h to NPK A/B plants by using

the ammonia transfer pumps and existing ammonia preheater.

Flare System

A Hot Flare system shall be provided for the Ammonia tank (for emergency purposes). Thermal

relief valves are provided in sections of pipelines where liquid Ammonia can get blocked in.

Site map showing location of the existing Horton spheres and proposed atmospheric pressure tank

is presented in Figure 7-1.

Figure 7-1: Site Map Showing Existing and Proposed Liquid Ammonia Tanks

7.1.5 Input Data for QRA

Weather data

Weather data for site used in risk analysis is listed in Table 7-2.

Table 7-2: Weather Data for Goa

Month Temperature (C) Relative Humidity (%)

January 31.2 21.5 69 61

Existing Horton

Spheres

Proposed Atmospheric

Pressure Ammonia

Tank






Month Temperature (C) Relative Humidity (%)

February 30.7 22.2 72 65

March 31.5 24.3 75 69

April 32.4 26.3 74 70

May 32.6 26.9 75 72

June 30.2 24.9 86 83

July 28.9 24.2 86 86

August 28.6 24.1 89 86

September 29.5 24.1 87 83

October 31.4 24.5 80 76

November 32.7 23.5 66 65

December 32.4 22.5 63 61

Wind rose diagram showing annual distribution of wind direction and wind velocity is shown in

Figure 3-2, Chapter 3.

Generic Failure Rate Data

This QRA study is based on generic failure rate data as available in the following publications.

OGP Risk Assessment Data Directory Report No. 434-3: Storage Incident Frequencies published by

International Association of Oil & Gas Producers.

Guidelines for Quantitative Risk Assessment “Purple Book” – Doc. No. CPR 18E.

The input data for QRA including the estimated failure rates is shown in Table 7-3.

Table 7-3: Failure case data for QRA

S.

No. Description Leak Size

Material

& Phase

Temperature

(C)

Pressure

(kg/cm2g)

Leak

Frequency

(per year)

A Existing Horton Spheres for Ammonia Storage (2 Nos.)

1 Ammonia

Tank failure Catastrophic

Failure Liquid

Ammonia 5 4

1.0E-06 (each tank)

2 Liquid outlet pipe failure

Line Rupture Liquid

Ammonia 5

4 (+ Liquid head in tank)

1.0E-05 (each tank)

B Proposed Atmospheric Ammonia Storage Tank (1 No.)

1 Ammonia

Tank failure Catastrophic

Failure Liquid

Ammonia (-)33 450-900 mm WCg 2.5E-08

2 Liquid outlet pipe failure

Line Rupture Liquid

Ammonia (-)33

400 mm WG (+ Liquid head in tank)

1.0E-05

Note: 1.0E-06 per year denotes 1.0 x 10(-)6 per year

7.1.6 Study Results

Consequence Analysis Results

Results of consequence analysis by Phast software for leak from 100 mm diameter hole are

summarized in Table 7-4.






Table 7-4: Consequence Analysis Results

Description

Down Wind Distance (Meters)

Weather 2 m/s; E 3 m/s; D 5 m/s; D

Parameter

Horton Sphere:

Liquid ammonia leak – 100 mm size

IDLH: 300 ppm ammonia 4439 3101 2709

ERPG-3: 750 ppm ammonia 1959 1629 1424

Atmospheric Pressure Tank:

Liquid ammonia leak – 100 mm size

IDLH: 300 ppm ammonia 1705 890 753

ERPG-3: 750 ppm ammonia 860 422 380

It is seen that the downwind distances for toxic dispersion of ammonia in case of leak are much

less in case of atmospheric ammonia tank compared to Horton sphere.

Horton sphere is semi-refrigerated type storage in which liquid ammonia is stored at about 4

kg/cm2g pressure and 5C temperature. Release of liquid ammonia under pressure by leak from

Horton sphere will cause much flashing of vapor due to depressurization and formation of liquid

droplets which will be carried over in the air. This will result in ammonia vapor dispersion over

long distance.

In contrast atmospheric tank is fully refrigerated type storage in which liquid ammonia is stored

close to atmospheric pressure at (-)33C temperature. In case of release of liquid ammonia by

leak from atmospheric tank there will be very little flashing of vapor. The dispersion will be mainly

due to vaporization of liquid ammonia falling on the ground close to the tank.

QRA Results

Results of QRA are presented in the form of iso-risk contours for individual risk.

The iso-risk contours for location-specific individual risk due to the two horton spheres in the

existing facility are shown in Figure 7-2.

Figure 7-2: Is-Risk Contours – Existing Horton Spheres (2 Nos.)

1E-06/year






The location-specific individual risk at eastern boundary of the plant near the Horton Sphere area

is found to be 3E-06 per year.

The iso-risk contours for location-specific individual risk due to the proposed atmospheric ammonia

tank are shown in Figure 7-3.

Figure 7-3: Is-Risk Contours – Proposed Atmospheric Ammonia Tank (1 No.)

The location-specific individual risk at the plant boundary near the proposed atmospheric ammonia

tank area is found to be within 1E-07 per year.

Conclusions

The conclusions of QRA study for ammonia storage at ZACL, Goa comparing the existing Horton

spheres and proposed double wall double integrity type atmospheric tank are as follows.

In the double wall double integrity tank, the inner tank and outer tank each can contain the liquid

ammonia inventory safely. Therefore In comparison to Horton sphere, the likelihood of failure of

double wall double integrity tank is negligible. According to the best industry practice, double wall

double integrity tank has proven to be the safest mode of storage of liquid ammonia.

Results of QRA clearly indicate that the individual risk at plant boundary is very much reduced by

replacing the Horton spheres by atmospheric ammonia storage tanks.

Individual risk at plant boundary in case of Horton spheres: 3E-06 per year

Individual risk at plant boundary due to atmospheric tank: 1E-07 per year

Based on the above factors, it is concluded that replacement of the two Horton spheres each 3000

MT capacity with one double wall double integrity type atmospheric tank of 5000 MT capacity will

result in considerable reduction of risk and enhancement of safety. This also conforms to the best

industry practice for liquid ammonia storage.

Recommendations

While implementing the installation of double wall double integrity type atmospheric ammonia tank

the following points need attention.

1E-07/year

1E-06/year






1. Liquid ammonia product stored in the atmospheric ammonia tank should contain not less than

0.2% water to prevent stress corrosion cracking in low temperature carbon steel (LTCS)

plates of the tank.

2. Proper quality assurance/ quality control programme including positive material identification

(PMI) should be followed to ensure that only the material (plates, pipes, fittings, welding etc.)

conforming to the specifications are installed.

3. Safety instrumented system with adequate reliability/ redundancy should be provided for tank

overfill and overpressure protection based on safety integrity level (SIL) analysis.

4. While commissioning the tank due care should be taken for removal of air from the system by

purging with adequate quantity of nitrogen to prevent stress corrosion cracking due to

presence of oxygen.

7.2 ONSITE EMERGENCY MANAGEMENT PLAN

Name and Address of the Person Furnishing the Information

Particulars Telephone nos.

Office Residence

Factory Manager

Mr. Ranjit Singh Chugh

Chief Manufacturing Officer Zurinagar, Goa- 403726

0832 2592418 0832 2592501

In charge Fire & Safety

Mr. G. S. Lotlikar

Chief Manager-Fire & Safety Zuarinagar, Goa- 403726

0832-2592549 0832-2592537

In charge of Occupational Health

Dr. A.G. Vaidya

Deputy General Manager-Medical Zuarinagar, Goa- 403726

0832-2592602 0832-2592517

Contact nos. In case of any emergency

FIRE STATION: 3992101, 3992622 SECURITY : 3992100, 3992603

OCCUPATIONAL HEALTH CENTRE : 3992102 EMERGENCY CONTROL CENTRE : 3992111, 8805060002

7.2.1 Introduction

Disaster is a major emergency which has the potential to cause serious injury or loss of life and /

or which tends to cause disruption inside or outside the works and requires the use of outside

resources. The emergency is termed "on-site" when it confines itself within the factory even

though it may require external help and "off-site" when the emergency extends outside the factory

premises. It is to be understood that if emergency occurs inside the plant and could not be

controlled, it may lead to an "off-site emergency". It is imperative that plant emergencies like fire,

explosions are by nature fast acting and the control system would normally be of prevention from

spreading, rescue and relief work. The planning for emergency will thus incorporate resources and

action for concentrating on evacuation, containment and relief work. On the other hand in case of

disaster due to toxic gases, the measures will be on long-term basis and will depend upon the

distance and weather condition. We have adopted an "ON-SITE EMERGENCY MANAGEMENT

PLAN" to instill confidence in employees and public to tackle any situation that may arise.






The plan complies with the legal responsibility of the Occupier of the Factory as per Section-41B

(4), 1948 and Rule 13 of the Goa Control of Industrial Major Accident Rules, 1991 and also under

Manufacture, Storage and Import of Hazardous Chemicals Rules, 1989 (MSIHC). It also complies

with the elements of the On-site Emergency Plan suggested in the Guidelines on the Chemical

(industrial) Disasters issued in May 2007 by National Disaster Management Authority, set up under

the Disaster Management Act, 2005.

The recommendations made by National Disaster Management Authority during mock drill

conducted on November 13, 2009 have also been implemented in this revision.

7.2.2 Key Personnel and their responsibilities

The Emergency Management Plan spells the transition from normal operation to emergency

operations and effective delegation of the authority from operations personnel to emergency

response personnel. An emergency response organization has been identified with appropriate

lines of authority and how the response management will take over. Each responder’s position in

the emergency organization, line of reporting, responsibilities and duties have been identified and

clearly defined.

7.2.3 Concept of Emergency Response Operation

During any emergency in the factory, the effectiveness of the plan depends upon how fast and

effective is the communication system among the responders and the other agencies involved in

handling emergency.

We have developed a communication system for 24-hour notification of the first responders and

other coordinators who will provide necessary direction and control. An “alternate” person is also

identified for each key position of the designated authority. The plan also includes a list of

alternate personnel for each emergency response and their contact number.

A procedure of a call to one person/agency who in turn calls one or more key individuals during

emergency is used so that all the levels in the organization are communicated.

7.2.4 Emergency organization

Command and control of an emergency condition encompasses the key management functions

necessary to ensure the health and safety of workers, as well as community living in the vicinity,.

In addition, the implementation of an Emergency Response Plan relies on a number of response

functions, which deals with different aspects of the emergency, with the most important ones

being:

Communication and coordination between coordinators;

Emergency Control system at Incident site & Emergency Control Centre;

Firefighting and Rescue;

Medical Services;

Security & traffic control;

Liaison with Govt. as well as external support agencies;

Administration (Transport, welfare).






Figure 7-4: Emergency Management Organization

7.2.5 List of Key Persons

S.

No. Role Location

1. Overall in charge: (Chief Manufacturing Officer )

Alternate –CGM-CS /CGM-O ECC

2 Chief Coordinator :Chief GM-Operations/GM-Manufacturing

Alternate –DGM-Concerned Plant Site

3. Maintenance Coordinator: DGM-Maintenance & Civil

Alternate – SM-Mechanical (Nitrogen) Site

4. Environment & Technical Coordinator: Head-Projects & TS

Alternate –CM-TS/ Dy.GM.-Prod (unaffected) Site

5. Medical Coordinator: SM-Medical

Alternate – Nurse on duty Health Centre

6. Site Coordinator: DGM- concerned Plant

Alternate – CM-concerned Plant Site

7.

Fire & Safety Coordinator: CM-Fire & Safety

Alternate – M-FS

One of the Officer from F&S will report to ECC depending upon availability.

Site/ECC

8. Security Coordinator: CM-HR&S

Alternate – Manager-Security (NISA) Site






9. Welfare Coordinator : Manager-HR

Alternate : SM-CSR&PR ECC

10. Communication Coordinator: Sr. Manager-PH

Alternate: Manager-Stores ECC

11. Incident Controller*: CM/SM/Mgr (concerned Plant)

Alternate – In charge (Concerned Plant) Site

12.

Other Key personnel’s

DGM’s from Unaffected Plants

& CM’S from Unaffected Plants

DGM’s - ECC;

CM’s - as per the instructions from Chief Coordinator

* In charge of the concerned plant, shall rush to the site along with his team and take charge till

arrival of Site Coordinator. (Concerned Plant DGM).

7.2.6 Duties and responsibilities of key personnel

Overall In-charge

The Overall-in-charge has an overall responsibility for directing operations and calling outside help.

Chief Manufacturing Officer (CMO) will take charge as Overall in-Charge. During his absence, Chief

General Manager-CS (CGM-CS) /Chief General Manager-Operations (CGM-O)or will act as Overall

In-Charge. He will decide upon the activation of Emergency Control Centre (ECC) depending upon

the prevailing wind direction. If required, he can activate the Mobile Emergency Control Centre.

The ECC is allocated next to Fire Station while alternate ECC is located at DAP gate. Overall in-

Charge will rush to ECC and perform roles/responsibilities as under.

1. Continually review and assess existing & possible developments to determine the most

probable course of events and effective methods to deal with them;

2. Ensure that casualties are receiving adequate attention;

3. Decide in consultation with Chief Coordinator & key persons whether an off-site emergency

exists or is likely to take place. If an off-site emergency exists;

o To alert evacuate the public living in the vicinity of the plant;

o Call the outside emergency services;

o Inform district emergency authorities;

o Coordinate with district emergency authorities to mitigate the consequences outside the

factory;

o Coordinate with District Emergency Authorities for evacuation, shelter, rescue &

rehabilitation of general public in the vicinity of affected area.

4. Issue authorized statements to the press or the media;

5. Inform MD regarding the status and action taken;

6. Rehabilitate the affected area after the emergency is over;

7. In case of strike by the plant personnel, identify critical areas of the plant in advance. If

emergency occurs during the strike, following arrangements required to be made in advance;

o Keep the list of technical records needed to run the factory in an emergency and train the

team.

o Keep the records of Personnel (Non-executive) likely to be available during the strike and

keep the same in safe custody.

o Identify the alternate arrangements for meeting any emergency, ie by mutual aid with

other factories, etc.






Chief Coordinator

Chief General Manager-Operations (CGM-O)/General Manager- Manufacturing (GM-M) will act as

Chief Coordinator. Deputy General Manager (DGM)-of the Concerned Plant will act as alternate in

case of absence of CGM-O/GM-M. The senior most available i.e. Plant in charge (Chief

Manager/Sr. Manager) or Shift In-charge for that shift will work as Site Coordinator till the arrival

of seniors in case the emergency occurs after Office hours or on holidays,.

After getting information about the emergency from the shift-in-charge/CM-concerned or on

hearing emergency, he will inform Chief General Manager-Operations who in turn will inform Chief

Manufacturing Officer (CMO). Chief Coordinator will report to the incident site and will operate

from the location nearest to the site.

The responsibilities are as follows:

1. To assess the magnitude of the situation and decide whether a major emergency exists or it is

likely to convert into a major emergency, requiring external assistance. He will instruct to

sound the coded emergency siren;

2. To exercise direct operational control over the areas other than those affected;

3. To communicate to Asst. Manager–Environment to monitor the environment for toxic gases

and effluent;

4. After assessing the magnitude of the situation, he will decide whether the persons inside the

factory are to be evacuated to pre-identified safe places;

5. To have a constant liaison with the authorized coordinators for ensuring that the casualties

are receiving adequate attention and traffic control movements within the works is well

regulated;

6. To communicate about the emergency to higher ups;

7. To arrange to inform Chief Inspector of Factories, District Collector, Police, Village Sarpanch,

Goa State Pollution Control Board, Fire Brigade, (Vasco-da-Gama) if required through

Communication Coordinator;

8. To arrange for collecting and preservations of evidences to facilitate any enquiry into the

causes and circumstances which cause or escalated the emergency. He shall arrange for the

photographs, video filming, logbooks, operating charts etc.;

9. To make assessment of total no. of casualties, damage incurred to plant, Property and

machinery and damage to environment during emergency;

10. After establishing normalcy from Emergency, Health Centre and other plants, he will authorise

to sound ALL-CLEAR SIREN.

Site Coordinator

Deputy General Manager of the concerned Plant would be Site Coordinator. In his absence Chief

Manager/Sr. Manager of the concerned plant will take charge as Site Coordinator.

1. After getting information about the emergency from the shift-in-charge/CM-concerned or on

hearing emergency he will inform:

o GM-M;

o DGM’s unaffected plant;

o CM’s of other plants reporting to him.

2. He will report to the incident site and take over charge from the shift-in-charge and work

under Chief Coordinator;






3. He will assess the extent of emergency and decide if a major emergency exists or is likely to

develop and also to decide to summon help if so required in consultation with Chief

Coordinator;

4. To take the command of the emergency at site, and co-ordinate all activities to bring situation

under control within shortest possible time. He will coordinate with the concerned Chief

Manager’s regarding shutting down of the plant, if required;

5. To coordinate with Maintenance Coordinator, Fire & Safety Coordinator for the help;

6. To ensure that the emergency is curtailed to cause minimum loss to the persons, machine and

environment;

7. To decide evacuation of plant personnel of the areas likely to be affected;

8. Make sure that all hot jobs have been stopped and assist Manager/Shift-in-charges in

normalizing the emergency.

Maintenance Coordinator

Dy. General Manager-Maintenance & Civil will act as Maintenance Coordinator. In his absence, Sr.

Manager-Mechanical (Nitrogen) will act as Maintenance Coordinator.

1. After getting information from the concerned ECC or Chief Manager/Sr. Manager or on hearing

siren he will inform:

o Sr. Manager’s-Mechanical;

o Sr. Manager-Central Maintenance (Mech);

o Manager-Civil;

o Centralised Shift Office.

2. To rush to the site, assess the situation and facilitate maintenance support to Chief

coordinator, needed to tackle the emergency;

3. To mobilise and coordinate the teams from Maintenance Department for isolation,

disconnection of equipment making bunds, repair activities, to control / mitigate effects of the

emergency;

4. To arrange for isolation of electrical lines (if required), facilitate lighting arrangements at

affected locations, assembly points. Chief Manager-Electrical and his team will assist

Maintenance Coordinator;

5. To arrange earth moving equipments like Cranes etc. (if required) for handling the

emergency;

6. To arrange workshop facilities with adequate manpower (if required);

7. To arrange for emergency procurement of material from local dealers or from other industries,

additional manpower (contract) through Purchase.

Environment and Technical Coordinator

Head- Projects & Technical Services (H-P&TS) will act as Environmental and Technical

Coordinator. His Alternate will be Chief Manager -Technical Services (CM-TS). After General Shift

hours and/or Holidays, one of the Dy. GM- Plant of unaffected plant will take the charge of

Environment and Technical Coordinator in absence of H-P&TS/CM-TS.

After getting information from Emergency Control Centre or on hearing Emergency Siren, he will

inform;

o CM-TS

o CM-Projects

o CM-Inspection

o Stores in charge






1. Rush to the incident site and identify the hazards.

2. Facilitate monitoring/analysis of the area inside and outside the factory premises (if required)

through laboratory in charge and keep Chief Coordinator informed about the results;

3. Remain in touch with the site coordinator and shift-in-charge for taking samples and rendering

help for plant personnel;

4. Inform the concentration of toxic gases to Overall in Charge and Chief coordinator and

Medical Coordinator;

5. Arrange for analysis of liquid effluent discharge from the factory if any;

6. Maintain record of base data and the conditions prevailing during emergency.

Fire & Safety Coordinator

Chief Manager-Fire & Safety (CM-F&S) will act as Fire & Safety Coordinator. In his absence,

Manager-Fire & Safety (M-FS) will act as Safety Coordinator.

After getting information from ECC or on hearing Emergency Siren, he will inform Manager-Fire &

Safety

He will report to the scene of emergency and perform the duties and responsibilities as follows:

1. To take charge of fire fighting responsibility under the guidance of Chief Coordinator;

2. To arrange for additional firefighting equipment/material like hoses, branch pipes, fire

extinguishers, foam compound, fire suits, breathing apparatus etc;

3. To advise Chief Coordinator regarding external help and direct outside fire fighting services

whenever called for;

4. To assist the employees in the rescue operation & use of safety appliances;

5. To brief Chief Coordinator about overall emergency and safety procedures followed during the

emergency.

Security Coordinator

Chief Manager-HR & S (CM-HR&S) will act as Security Coordinator. In his absence, Manager-

Security (NISA) will act as Security Coordinator.

After getting information from Main Gate House or on hearing Emergency Siren, he will inform;

o CGM-CS

o M-HR

1. Rush to the Incident Site and report to Chief Coordinator;

2. Control the traffic movement in and out of the factory. This involves both movements of

vehicles and the persons;

3. Maintain Law and Order and to avoid gathering of personnel at the scene of emergency.

Cordon off the affected area;

4. Provide assistance to Fire & Safety Coordinator for firefighting or for removing the casualties

or supply of safety appliances etc.;

5. Keep liaison with Police;

6. Direct external help from local authorities to respective coordinators;

7. He will be responsible for public announcement of the hazards and action to be taken on

Public Address System;

8. Arrange for vehicles from outside local transport agencies in case of need;

9. Assist Site Coordinator, Medical Coordinator, Fire & Safety Coordinator for the transportation

of victims from the affected area to safe places.






Medical Coordinator

Sr. Manager-Medical (SM-M) will act as Medical Coordinator. In his absence, the Male Nurse on

duty at the Health Centre will act as Medical Coordinator.

On getting information from Health Centre, he will rush to the Health Centre and perform the

duties and responsibilities as follows:

1. Call the trained First Aiders from the unaffected plants/township;

2. Arrange for additional doctor (if required) and ambulances;

3. Have liaison with local medical authorities and hospitals in case the casualties are more and

situation demands treatment from additional Medical Centres;

4. Ensure the up-keep of medical supplies, antidotes for treating victims for burns and hazardous

chemicals;

5. Remain in touch with Overall-In charge and Chief Coordinator for any help required;

6. Liaison with Security Coordinator for the transportation of the injured to the Hospitals.

Communication Coordinator

Sr. Manager-Product Handling (SM-PH) will act as Communication Coordinator. In his absence

Manager-Stores (M-S) will work as Communication Coordinator.

After getting information from ECC or on hearing Emergency Siren, he will rush to Emergency

Control Centre and report to Overall In-charge;

1. Take charge of communication through telephones, messengers, Walkie-talkie sets etc.;

2. Arrange for announcements on public address system and maintain contacts with Canteen,

Main Gate, Control Room, Fire Station etc;

3. Maintain a log of major emergency with timings about the various communications received /

passed from the Emergency Control Centre;

4. Seek help/assistance from the other coordinators reporting to ECC in case of need.

Welfare Coordinator

Manager-HR will act as Welfare Coordinator. In his absence Sr. Manager-CSR & PR will act as

Welfare Coordinator.

After getting information from Security Coordinator or on hearing Emergency Siren, he will inform;

o CGM-HR

o SM- CSR & PR

He will rush to Emergency Control Centre and report to Overall In-charge;

1. Arrange for supply of food and beverages to emergency fighting crew both from inside and

outside agencies as and when required;

2. Arrange for supply of food and other necessary items to injured and affected persons;

3. Intimate about the casualties to the relatives of the injured persons;

4. Keeps record of attendance of emergency fighting crews and exact number of people inside

the factory;

5. Assess the situation in the surrounding areas;

6. Evacuate colony and affected areas and make arrangement for shifting them to alternate safe

places, if required.






7.2.7 Responsibilities of the key persons during emergency

Shift-in-charge (Concerned Plant)

1. Proceed to the emergency site, assess the situation and inform;

o Fire Station /Emergency Control Centre (101, 2622, 111) giving the details, type of

emergency;

o Inform Chief Manager/GM-M.

2. Till the arrival of the designated Chief Coordinator act as Chief Coordinator;

3. Initiate the control operations for controlling the hazards;

4. Do not allow any person to enter the area without required PPE’s;

5. Direct rescue operations with the help of fire, Safety & Security staff;

Civil Coordinator: (Sr. Manager-Civil/Manager -Civil)

1. Rush to the scene of the emergency after getting information from Maintenance Coordinator

or on hearing emergency siren;

2. Mobilize contractors, contract workers and heavy earth moving equipment to carry out civil

jobs like making bunds, closing drains, filling sand bags, excavation as per the requirements

during the emergency;

3. Be available at the incident site and constant in touch with Maintenance Coordinator and Site

Coordinator.

Public Relations Coordinator: (Sr. Manager-CSR & PR)

1. On getting information from Welfare Coordinator or on hearing emergency siren, he will report

to Emergency Control Centre. He will work directly under Overall In-Charge;

2. He will also carry out the role of Welfare Coordinator in absence of M-HR;

3. He will release the authorized information, statements from CMO to the media & Press.

Essential Staff

Plant Technicians and plant staff shall remain in the plant and take the corrective action,

safe shutdown action depending upon the instructions/directions from the concerned sectional

heads and superiors. The maintenance staff of respective plants will be available at the plant

and will work under instructions from shift-in-charge/plant in charge/maintenance in charge;

Trained First Aiders of the respective plant/sections shall reach the incident Site and render

First Aid till assistance from Health Centre arrives and thereafter assist the Medical Team. The

trained first Aiders from non plant areas should report on hearing emergency siren or on call

from Medical coordinator and follow instructions from him;

Trained Fire Fighters of the effected site (including those of service Dept) shall reach the

incident site to help the Fire Fighting and mitigating the emergency. They shall remain at site

to assist the fire fighting and follow the instructions/directions from Fire & Safety Coordinator.

The trained fire fighters from other unaffected plants/sections should get in touch with ECC;

The Security Guards in their respective posts within the factory and at other posts shall not

allow any unauthorized entry or person. They shall properly guide Goa Fire & Emergency

Services, Mutual Aid Group and other external authorities whenever called for to the incident

site. They will keep inform about any abnormal movements/activity to the Security

Coordinator/Main Gate.






7.2.8 Actions by the other persons present

On hearing emergency siren, all the persons who are not a part of response teams would

immediately evacuate their place of work and proceed to the nearest Assembly Point. The

concerned officers will be responsible to evacuate the visitor to the Assembly Point.

Locations of the Assembly Points along with in-charges are as under:

Assembly

Point Location Person Assembling In charge

AP-1 Ammonia/Urea Ammonia/Urea Operation Staff Ammonia Shift

Manager

AP-2 Power Station Power Station Operation Staff Shift Manager

AP-3 Water

Treatment Water Treatment Operation Staff Shift Manager

AP-4 NPK-A Operation staff & Contract Staff Shift Manager

AP-5 NPK-B Operation staff & Contract Staff Shift Manager

AP-6 NPK-A & B

maintenance office

Field maintenance staff of NPK-A & B & contract staff

Manager-Mechanical

AP-7 PH Office Operation Staff & Field maintenance PH/RMH Shift Manager

AP-8 Passage in front of instrument

dept.

Laboratory, Instrument workshop, electrical workshop & mechanical workshop , Stores,

maintenance office staff

Manager-Instruments

AP-9 Near Fire Station Works Office Staff , Tanker crew of furnace oil &

Ammonia, Visitors and Works Canteen Staff ECC coordinator

AP-10 Behind

DAP/Bagging

Phosphoric acid, Sulphuric acid tanker crew, Stacking & unshackling gangs of monsoon shade,

Contract bagging staff & Labour canteen NEHA foreman

AP-11 In front of Jai

Kisaan Bhawan For Administration Staff, SBI staff , drivers and

Adm. Visitors M-HR/SM-P&IR

It is the responsibility of all job in charges to train the personnel including the contract staff

working under him as to how to assemble safely to the designated Assembly Point and to

listen and follow the instructions issued by the in-charges of the Assembly Point;

It is the responsibility of the Sr. Officials to direct the Visitors, service providers to assemble to

the nearest Assembly Point and follow the instructions;

It will be the responsibility of the concerned Assembly Point In-charge to shift the personnel

under his charge to the other Safest Assembly point depending upon the wind direction;

In case any person is suspected to be missing, the Assembly Point in Charge should inform

the Overall In-Charge and Chief Coordinator;

After “ALL CLEAR” siren, all Assembly point in-charges will report to ECC with the list of Roll

Call.

7.2.9 Outside organizations if involved in assisting during On-site Emergency

In case any emergency going out of control and requires any external help, the same will be

decided by the Overall In-Charge in consultation with the Chief Coordinator. The communication to

these external agencies will be made by Communication Coordinator from ECC. Either Chief

Manager-Fire & Safety/Manager-Fire & Safety/Fire & Safety Officer will assist the Communication

Coordinator in this communication.






7.2.10 Statutory bodies and their addresses

S. No. Statutory bodies Telephone Fax

1 Inspectorate of factories & boilers

a. Chief Inspector of Factories & Boilers

Institute of Occupational Safety, Health

& Environment,

Altinho, Panaji-Goa

2227670,

2226181 2226510

b. Inspector of Factories


& Environment,

Altinho, Panaji-Goa

2226181 2226510

c. Inspector of Boilers


& Environment,

Altinho, Panaji-Goa

2226181 2226510

2 Goa State Pollution Control Board

a. Chairman

Goa State Pollution Control Board

Patto Plaza

Panjim-Goa

2438563 2438528

b. Member Secretary

Goa State Pollution Control Board

Patto Plaza

Panjim-Goa

2438563 2438528

3 Dept. of Explosives

a. Chief Controller of Explosives

Dept. of Explosives, C.G.O. Complex

5th Floor, Seminary Hills,

Nagpur-440 006, MAHARASHTRA

(0712) 2510248, 2510579

b. Joint Chief Controller of Explosives

A-1 & A-2 Wing, 5th Floor, C.G.O Complex

CBD, Belapur

Navi Mumbai (MAHARASHTRA) 400 614

(022) 27564941

List of Govt. Officials and their contact details

Designation of

Person

Contact Number

Office Mobile Residence

STATE GOVT. OFFICIALS

Chief Secretary 2419402 - -

Collector-North Goa 2223612 9822123071 2420710

Collector-South Goa 2705333 9423884900 -

Dy. Collector, Mormugao 2512688 9822588399 -

Supdt. of Police-North 2416100 -

Supdt. of Police-South 2732218 - -

Dy. Supdt. of Police-Mormugao 2500222 - -

PI, Verna police Station 2782325 - -

PI, Vasco Police Station 2512304, 2513273 - -

PI, Harbour Police Station 2520740 - -

Director, Goa Fire& Emergency Services 2225500, 2227616 9763717044 2225033






Designation of

Person

Contact Number

Office Mobile Residence

Station Fire Officer, Vasco 2513840 9763717056 -

Station Fire Officer, Verna 2887122 9763717060 -

Asst. Divisional Officer, Margao 2714600, 2715825 9763717052 -

Chief Inspector of Factories & Boilers 2227670, 2226181 9411440008 -

Inspector of Factories 2404876 -

MAJOR HOSPITALS

Goa Medical College 2458700, 2458702 - -

SMRC 2540218, 6691919 - -

MPT Hospital 2512768 - -

Hospicio Hospital 2705754, 2704363 - -

7.2.11 Details of Liaison Arrangement between the Organisations

Mutual aid and response group

Details of liaison arrangement between the mutual aid partners are worked out. Then an

agreement is signed between all the mutual aid partners. The agreement contains all the

procedures like communication, place of reporting, responsibilities and duties during the

emergency. The outside agencies from whom the assistance will be sought are Mormugao Port

Trust, Indian Navy, Goa Shipyard Ltd., Indian Coast Guard.

The mutual aid partners will be made aware of various types of hazards in each plant and the

existing fire fighting system.

Mock drills with mutual aid partners will also be carried out at regular intervals.

S.

No. Name of contact person

Telephone nos.

Office Residence

1. Central Fire Station-MPT 2521300, 2594812 2522690

2. Indian Coast Guard 2520584, 2521051 -

3. Goa Shipyard Ltd. 2512152- 2512156 2540912

4. Duty Staff Officer-Indian Navy 2582200 -

5. Terminal Manager -IOC 2513067, 2512617 2521856

7.2.12 Preliminary Hazard Analysis

Type of Accident, system elements & Hazards

Type of Accident System Elements or Event that can lead

to the Main Hazard Hazard

Ammonia leakage Ammonia Hortonshere

Process area

Transfer line

Ammonia Unloading Station

Toxic release

Fire Hazard

Spillage of Corrosive chemicals

Acid storage: H2SO4, H3PO4

Alkali (NaOH) storage

Process lines

Acid, caustic unloading area

Acid and alkali burns

Acid spills in small,

medium and large

quantities

Spillage and Fire HSD storage

Oil console in process area/compressor

Pool Fire

Fire Hazard






Type of Accident System Elements or Event that can lead

to the Main Hazard Hazard

Empty bag storage area in PH

Chlorine leaks Chlorine tonners

Chlorine pipelines/manifolds

Toxic release

Fire & Explosion Process area

GAIL metering station/terminal

Gas line from GAIL to process plants

Fire/pool fire

Flash fire explosion

VCE

Boiling Liquid Expanding

Vapour Explosion (BLEVE)

Boilers BLEVE

High Pressure Component

Rupture

System Elements/Events that can lead to major accidents, hazard and safety related

components

Ammonia storage handling facility

Existing Horton sphere storage will be converted to Atmospheric Ammonia Storage Tank (Double

wall, Double Integrity tank) which is more safest technology to store Ammonia.

Chlorine storage and handling area

At ZACL, Chlorine is used in following three locations:

Water Treatment Plant

Cooling Tower-I

Cooling Tower-II

The following are the safety features incorporated:

Chlorine detector is provided to detect ant leak of Chlorine. These detectors generate an

alarm in the Water Treatment Control Room;

Chlorine emergency kit is provided at the Chlorine handling location;

Chlorine Absorption system is also provided which automatically will start on leakage of

Chlorine and will neutralize with NaOH solution;

Self Contained Breathing Apparatus and specialize suits for handling Chlorine are provided at

Chlorine Handling area;

Eye was and Safety Showers are provided;

PPPE’s like Protective clothing, gloves, face shield, goggles, canister gas masks are provided

for the persons handling Chlorine;

The trained technicians/employees are employed.

Boilers

The Boilers are designed and fabricated as per the relevant codes and standards and installed

after due approval from Chief Inspector of factories & Boilers, Goa.

All the boilers are offered to the Annual survey to the Inspector of Boilers;

Boilers have inbuilt Boiler Management System logic for safe and smooth normal operation,

start-up/shutdown;

Logic like conditions of purge ready to start, burner ready to start, tripping on Natural Gas,

tripping on furnace pressure, furnace pressure high, drum level low etc are incorporated in

the BMS logic;






Safety valves are provided at each Boiler drum and Super heater steam line;

Reliable instrumentation, including level gauges & transmitters are provided on each boiler.

HSD storage, Furnace oil Storage (both at power station), transformer areas and Oil

console

Adequate nos. of extinguishers are provided, tested and maintained;

Fire hydrant system is provided near and around the area;

Dykes are provided for HSD and Furnace Oil storage areas;

Manual Call Points are provided;

Sufficient nos. of sand buckets is provided;

The areas are maintained free from combustible materials;

Steam hoses are also provided near oil consoles.

Storage of corrosive liquids like sulphuric & phosphoric acid, caustic lye

Bunds walls/dyke are provided;

Level gauges with indication and alarm is provided;

Eye wash and safety showers are provided near to the storage and handling area;

Manual call points are available;

The floor area is made acid proof;

Caution boards and what to do in case of spill are displayed;

Full protective suits, gumboots, goggles, gloves, face shield are provided to the person

handling corrosive liquids.

Details about the Site

Location of dangerous substances

Ammonia

Ammonia is an intermediate product which is in liquid state and vapor state. Ammonia is used in

the manufacture of Urea and complex fertilizers. Ammonia is fed to the plants through pipelines

and stored in hortonsphere. The ammonia is used/processed and handled in Ammonia plant, Urea

Plant, NPK-A, NPK-B and RMH plants.

Storage: Ammonia is stored in Hortonsphere which is located near Ammonia Plant. One

hortonsphre is always kept stand by

Chlorine

Chlorine is used in the treatment of water at water treatment plant. It is available in the connected

piping and manifold in Water Treatment plant.

Storage: Chlorine tonners are kept in Water Treatment plant under covered storage.

Hydrogen

Hydrogen exists in gaseous intermediate for manufacturing Ammonia. It exists in the process gas

and is not stored.

Carbon Monoxide

Carbon monoxide exists as gaseous intermediate which then gets converted into carbon monoxide

with steam in shift converters and exists in Ammonia Plant.






Phosphoric acid

Phosphoric acid is used as a raw material in NPK-A & NPK-B Plant. It exists in pipelines and

process equipment.

Storage: It is stored in tanks and day tanks in RMH, NPK-A & NPK-B plants.

High Speed Diesel (HSD)

HSD is used as a fuel for initial start up of Boilers, diesel generator is a fuel used for emergency

generator.

Storage: It is stored in tanks located at Power station

Sulphuric acid

Sulphuric acid is used as raw material for production of complex fertilizers and also for water

treatment. It is available in pipelines connected from storage tanks to the process equipment in

NPK-A, NPK-B, Water treatment and Utilities Plants.

Storage: It is stored in tanks located in NPK-A, NPK-B, RMH, Water Treatment and Utilities Plant.

Furnace oil

Furnace oil is used as a fuel in DG, NPK-A and NPK-B plants. It exists in pipelines connected from

day tanks to the boilers and furnaces.

Storage: Furnace oil is stored in storage tanks and day tanks located at Power Station, NPK-A

and NPK-B plants.

Caustic Lye (Sodium hydroxide)

Caustic lye is used for water treatment. It exists in pipelines.

Storage: It is stored in tanks at Water Treatment Plant.

Natural Gas

Natural gas is used as feed material for Ammonia Production and also as fuel in Boilers, and NPK

Plant. It is supplied through a gas pipeline from GAIL Terminal.

7.2.13 Seat of Key Personnel

The location and seat of the Key personnel during normal operations and during emergency is as

follow:

S.

No.

During normal operation During emergency

Designation Location Coordinator Location

1 Chief Manufacturing

Officer Admn. Block/B-Colony

Overall In-charge

Alternate –CGM-CS/ CGM-O ECC

2 CGM-O/GM-M Admn. Block/ Work

Office/B-Colony

Chief Coordinator

Alternate –DGM-Concerned Site

3 DGM-Maintenance &

Civil Maint. Office/ C-Colony

Maintenance Coordinator Alternate –SM-Mech.

Site

4 Head-Projects & TS Works Office /

B-Colony

Environment & Technical Coordinator

Alternate –CM-TS/Dy.GM.-Prod (unaffected)

Site

5 SM-Medical Health Centre

/C-Colony

Medical Coordinator Alternate –Nurse on duty:

Health Centre






S.

No.

During normal operation During emergency

Designation Location Coordinator Location

6 DGM-

concerned Plant

Works Office/

C-Colony

Site Coordinator

Alternate – CM-concerned Plant Site

7 CM-Fire & Safety Work Office/C-Colony Fire & Safety Coordinator

Alternate – M-FS Site/ECC

8 CM-HR&S Admn. Block/ C-Colony Security Coordinator Alternate –

Manager-Security (NISA) Site

9 M-HR Admn. Block/ D-Colony Welfare Coordinator Alternate :

SM-CSR & PR ECC

10 SM-PH (ISM) PH/ C-Colony Communication Coordinator

Alternate: Manager-Stores ECC

11 CM/SM/Mgr (concerned

Plant) Plant

Incident Controller

Alternate – In charge (Concerned Plant)

Site

12 DGM’s from Unaffected

Plants Plant/ C-Colony - ECC

13 CM’S from Unaffected

Plants Plant/ C-Colony - ECC

7.2.14 Emergency Control Centre

Two emergency Control Centres are set up:

Emergency Control Centre. (Alternate control centre at DAP gate). In case both the ECC are

not suitable, a mobile ECC in Emergency Rescue vehicle can also be set up;

Incident control room.

Location of ECC

Fire station is identified as Emergency Control Centre. The Control Centre will be the focal point in

case of emergency from where the overall operation to handle the emergency is directed and

coordinated. In case of adverse wind direction affecting the Emergency Control Centre, Emergency

Rescue Vehicle will be converted into Mobile Emergency Control Centre for this purpose. At all

Emergency Control Centers i.e. Fire Station, DAP gate and Mobile Centre the following information

is available.

Facilities available at ECC

Lay out plan of the complex, indicating all the plants, emergency control centre, roads, escape

routes, health centre, fire station, location of fire water pumps and highlighting hazardous

areas, location of wind socks, ammonia leak detectors;

List of fire fighting and safety equipment;

Population distribution map of surrounding area up to 10 km radius;

Copy of on-site emergency management plan;

List of telephone numbers of key personnel;

List of important telephone numbers like members of mutual aid scheme, fire brigade, police

station, District Collector's office, Chief Inspector's office, etc.;

Self Contained breathing sets (2 nos.), Explosive meter (1 no.), safety torches (2 nos.),

chemical suit (1 no.);

Walkie-talkie sets and Base station (set.);

Office facilities including internal telephones /external (3 nos.), Mobile phone (1 no) chairs,

table, stationary, etc.






Manning of ECC during Emergency

During any emergency, ECC will be manned by the following personnel:

Overall In-Charge and his alternate;

Communication Coordinator and his Alternate;

Welfare Coordinators and his Alternate;

Other Key Personnel like Dy. GM’s of unaffected plant, Public Relation Coordinator.

7.2.15 Description of Hazardous Chemicals at Plant Site

Chemicals (Quantities, Purity and Toxicological data)

Details of Chemicals in process

Hydrogen

Hydrogen is in gaseous intermediate for manufacture of Ammonia. This is produced and is not

stored. It is one of the constituent for manufacturer of Ammonia.

Carbon monoxide

Carbon Monoxide is a gaseous intermediate. This gets converted into CO2 with steam.

Details of Chemicals in storage

S.

No.

Name of

chemical

Toxicity Total Licensed/

Storage

capacity

No of

tanks/

storages

Purity of

chemical

Whether

transformation

could occur

1 Ammonia Toxic 5600 MT 2 99.6-99.8 No

2 Chlorine Toxic 6 Tonners 6 99.9 No

3 Phosphoric acid Corrosive 13264 MT 5 52-54% No

4 Caustic Lye Corrosive 56 MT 2 46% No

5 Sulphuric acid Corrosive 3107 MT 6 98-99% No

6 High speed diesel Flammable 24.8 KL 2 - No

7 Furnace oil Flammable 314 KL 7 100% liquid No

8 Process gases Flammable - - Varies No

Likely Dangers to the Plant

Risk assessment study has been carried out in April 2009 through NEERI, Nagpur with the aim to

estimate the distances likely to be affected in case of Ammonia release and impacts of fire. The

scenarios considered are summarized below with the following assumptions:

Stability Class F with wind speed 2 m/s and for class D with 3 m/s;

IDLH for Ammonia: 300 ppm.

Toxic/pool fire/jet fire/flash fire

TOXIC

1. Ammonia storage tank

Leak size 25 mm diameter

Source strength 0.38 Kg/sec

Toxic cloud

At stability class 2F: distance 261 m

At stability Class 3D: distance=235 m


Leak size 50 mm diameter


Toxic cloud

At stability class 2 F: distance 394 m

At stability Class 3 D:distance=470 m






Pool fire/Jet fire vapour cloud explosion/flash fire

3. Natural gas pipeline

Pressure: 40 Kg/cm2g

Flow rate: 1.65 MSCMD

Leak size 25 mm, Source strength 2.96 kg/sec

Flash fire

At stability class 2F

LFL distance-15.83 m

At stability Class 3D





Leak size 50 mm, Source strength 11.8 kg/sec

Flash fire








Catastrophic rupture, Source strength 86.35 kg/sec

Flash fire






Temp: 4 deg, C

Pressure: 4 kg/cm2g

Capacity 3000 MT

VCE At stability class 2F

bar, damage distance 901.65 m

At stability class 3D,

0.1 bar, distance-893 m


Pressure: 40 kg/cm2g


Leak size: 25 mm





0.1 bar, distance-38.79 m




Leak size: 50 mm

Source strength: 11.8 Kg/sec




0.1 bar, distance-101.18m




Catastrophic rupture




0.1 bar, distance-282.01 m

7.2.16 Natural and Manmade Calamities which can Lead to Emergency Scenerio

Goa exhibits low seismic activity (zone III) and has favourable location on the West Coast where

storms/cyclones are rare and mild. It is pertinent to note that even in Gujarat and Orissa 9

Paradeep), in spite of occurrence of major earthquakes as well as super-cyclones, Ammonia

storage tanks were unaffected and intact.

Incidents having off-site implications can be caused by:

manmade causes like air raids or crashing of aircraft

sabotage

A major emergency can originate from one or a combination of the following events:

Slow isolated fires

Fast spreading fires

Explosions

Bursting of pipelines/high pressure vessels






Other Incidents

Other incidents, which can also result in a off-site emergency are:

Agitation/forced entry by external group of people/vandalism

Bomb explosion

Effects of Stress & Strain cause during Normal Operation

In any industry during the plant operations, deviation from the normal condition is likely to occur

sometimes. These deviations may result in to certain stress and strain either in the equipment or

to controls. The stress and the strain generated so are nothing but the accumulation of the

chemicals/mechanical or electrical energy or a combination of these. This energy if not handled

properly may result in to the occurrence of hazard.

The stress and strain can be caused by corrosion & erosion, vibration and hammering.

Corrosion & Erosion

Ammonia, carbon dioxide, urea carbamate, acids etc. are corrosive in nature and can cause

corrosion to the equipment, vessels, piping’s etc.. Engineering controls have been taken in design

and operation to minimize or nullify the corrosion. For external protection, special paints are used.

Along with the engineering control regular monitoring are done to ascertain the health. The

techniques used are:

External checks if vessels, equipment, piping’s;

Regular monitoring by operations & service dept.;

Non destructive testing methods by our Inspection dept.;

Corrosion coupons are also used in cooling water lines to know the healthiness of heat

exchangers and pipelines;

Residual life assessment.

Vibration

Vibration is another phenomenon which can cause stress and strain during the normal operations

and may cause damage. Some of the reasons can be imbalance of rotating components, defective

support system etc. For critical machinery online vibration monitoring system with alarm and trip

systems have been installed from design stage. The indications are available in control room for

operator guidance. In addition inspection dept conduct regular monitoring and keep history; all

these data are utilized for analysis to know health and take appropriate actions in time to avoid

damages.

Hammering

Hammering is another phenomenon which can cause stress and strain on the structure and

pipeline. This can dislocate the pipes from it’s place and lines get damaged from different

locations. Hammering can be caused due to accumulation of condensate in lines. Adequate

precautions are like steam traps, condensate removal system, vent and drains are provided to

minimize this effect.

Fire and explosion inside the plant and effect if any of fire and explosion outside

Fire and explosions inside the plant can be caused in the systems associated with Natural gas,

process gases in vessels. There may not be any direct effect of fire and explosion outside.

We have adequate in built safety features, monitoring and fire fighting facilities.






7.2.17 Details regarding Warning, Alarm, Safety & Security Systems

Warning, Alarm, Safety & Security System

An audible emergency siren system is provided which can be operated from two locations viz.

from Ammonia Plant and from Fire Station/Emergency Control Centre.

There are 4 sirens located in the entire factory so that the siren is audible as follows:

Above Ammonia Control room

Roof of DG building

Above WTP control room

Above NPK truck loading in Bagging plant

In addition to above “Off-site Siren” is also provided on the DG building which can be sounded

from Emergency Control Centre.

In addition buzzers have been provided in NPK-A, NPK-B and Bagging Control rooms.

The sirens will operate as below:

Onsite Emergency Siren : Wailing sound for two minutes (4 seconds “on” & 2.5 seconds “off”)

Off-site siren : Wailing sound for 2.45 minutes (2.5 seconds “on” and 1 second “off”)

All Clear Siren : A continuous sound for a period of two minutes

Testing : All sirens /buzzers are tested on 1st Monday of every month at 10:30 a.m. from Ammonia Plant as well as from Emergency Control Centre

Safety System

ZACL has a good safety management system and a Fire & Safety Dept with qualified and

dedicated Safety Professionals. Necessary studies like HAZOP, QRA, EIA have been carried out

through reputed organizations like NEERI, EIL. The safety has been taken right from the design

stage. Any changes in the process/modifications are done under Plant Modification procedure

which involves HAZOP, Safety Assessment from Technical and Fire & Safety Dept. All the plants

have well established documented emergency shutdown procedures, safety relief system, early

warning and alarm system, round the clock monitoring of operations, uninterrupted power supply

etc.

All the jobs within and ZACL campus are carried out under a well documented Work Permit and

lock out tag out system. All the personnel including the contract workers have been provided with

PPE’s and action taken against the defaulters. 3 Tier Safety Committees are constituted involving

shop floor employees and meeting are conducted regularly. Safe Operations Committee headed by

MD are held once in 3 months.

For the involvement of contractor’s workers and also safe transportation of raw materials, separate

committees are constituted and action plan is drawn for implementation.

We have a system of reporting Make to Good condition/Near miss/incident/accident. The accidents

are investigated, analyzed and recommendations are implemented. All the accidents are reviewed

by Sr. Management.

The employees as well as the contract staff undergo fire & Safety training programs through

internal as well as through external faculties. Safety promotional activities are conducted to

motivate the staff.






Specialized community awareness programmes are conducted on regular basis in association with

District Administration and Inspectorate of Factories & Boilers, Govt. of Goa. Leaflets on Dos’ and

Don’ts of Ammonia and what to do in case of emergency distributed among the community.

Periodic internal as well as external audits are conducted and review of the same is done for

implementation.

Security System

ZACL factory & other ZACL estate area in Goa, including the ZACL colonies in segregated pockets

are spread safeguarded by of 80 security personnel. Security is provided at all vulnerable points

throughout the complex all round the clock. The main body of security personnel are in 3

categories i.e. guards, head guards & security inspectors. The entry and exit at all gates are

verified by the security and then only allowed. Cameras are provided at the main gate and railway

siding which are monitored by Security Head. Metal detectors are provided at the main gate and

the DAP gate. All the contract staff are physically checked at the entry and exit. The entry of the

employees and regular contract workers is recorded at the entry and exit points. The security has

one four wheeler and two wheelers for carrying out the security job.

Alarm and hazard control plan in line with Disaster Control and hazard control planning, ensuring

the necessary technical and organizational precaution.

Technical Support Services

S. No. Services

1 Toyo Engineering Corporation. Japan

2 Toyo Engineering (India) Ltd., Mumbai

3 Projects Development India Ltd., Sindri

4 Engineers India Ltd, New Delhi

5 National Environmental Engineering Research Institute, Nagpur

6 KLG-TNO, New Delhi

7 Confederation of Indian Industry

8 Tata Consultant Engineers, Mumbai

9 KBR, U.S.A.

10 Thermax

11 UHDE India Ltd.

12 BHPV, Vishakapatnam

13 LIQUE, France

14 Hindustan Dorr Oliver

15 INCRO, Spain

16 BHEL, Tiruchapally

17 TROJKA, Poland

Measuring instruments and control units and servicing of such equipment

Leak detectors have been installed in different plants depending upon the storage and handling of

the hazardous chemical. The types of detectors and their location depends upon probability of the

leak and it’s effect. Most of the detectors are connected to the plant control rooms. Manual Call

point alarms are available at Fire Station. All the detectors are calibrated periodically and checked

for working regularly.






The list of detectors with their type, location and nos. is as below:

S.

No.

Type Location Qty.

Ammonia Plant

1 NG leak detector -%LEL Reformer, combustion chamber 25

2 Ammonia leak detectors -PPM Storage and pump area 15

3 Ammonia leak detectors -PPM Ammonia Unloading 3

4 Smoke detectors compressor house 4

Urea Pant

1 Ammonia leak detectors -PPM Urea Plant - storage and pump area 4

Utilities

1 Ammonia leak detectors -PPM Water Treatment Plant 1

2 NG leak detector -%LEL Power Plant -burner area 5

3 Chlorine leak detector - PPM Pre- treatment in WTP 1

4 Smoke detectors DG room 2

Product Handling Plant

1 Smoke detectors Bag storage area 4

Incident control room will be established as soon as emergency occurs. The control room of the

affected plant will be the incident control room. Site Coordinator will send / receive communication

from this control room to persons concerned.

Telephone nos. of the incident control room shall be immediately conveyed to the Emergency

Control Centre or Alternate Control Centre.

7.2.18 Precautions in designing of the foundations and load bearing parts of the

building

Safety in design of foundations

Foundation of a structure is like the roots of a tree without which the tree cannot stand. Thus, the

Design of Foundation of and Civil Engineering Structure, may it be a simple Residence Building or

a Sky Scraper, is of paramount importance.

Foundations can be broadly classified as Shallow Foundations and Deep Foundations, depending

upon the difference of level between the ground surface and the base of the foundation.

A specific type of Foundation is adopted after undertaking extensive Geo Technical studies to

determine the type of soil and to ascertain the depth at which the hard strata is available.

While designing Foundations the following point should be borne in mind:

It is necessary that a Foundation is so designed that if at all a settlement should occur, then it

will be uniform ie the settlement for all the footings will be more or less the same.

All structures in Zuari Agro Chemicals Ltd. have been designed considering a Safe Bearing

Capacity of Soil as 20 tonnes per sq.mts. The foundations of structures in Zuari are resting on

hard lateritic strata.

Safety in design of load bearing parts

Load Bearing structures play a vital role in effective transfer of load to the foundations. As such, it

is of vital importance that they have to be designed properly after working out the loads that will

be transmitted to the various load bearing components of a structure. Correct Engineering






Practices as laid down in the National Building Codes have to be followed at the time of casting /

erection of the load bearing structures.

Some of the most common Load Bearing Structures of any Engineering structures are Beams,

Columns, Slabs, Shear Walls etc.

For enhancing the stability of load bearing Masonry walls, RCC bands are provided at the Plinth

level and below the roof slab level.

It is of paramount importance that a stability check of such load bearing structures is undertaken,

at least once in 5 years, to ascertain the health of the same. In Zuari Agro Chemicals Ltd., the

load bearing components of an RCC or Steel structure are tested once in every 5 years by

appointing an approved residual life assessment agency who carries out the inspection work by

using Non Destructive techniques like Rebound Hammer Testing, Visual Inspection etc.

Continuous surveillance of operations

Continuous surveillance of Operation of the process is done through the following online systems:

Continuous monitoring of the necessary process parameters from the centrally located control

room;

Continuous automatic process control from automatic Coordinators;

Continuous monitoring of the process analysis through process analyzers;

Emergency shutdown systems;

Quality control Laboratory.

This system enables the operators who work on shifts to be in complete command of the process

status.

Continuous Monitoring

This is being done by sensing the process parameters through dedicated transmitters, which in

turn send signals to the monitors in the control room. These monitors consist of analog and digital

indicators, recorders, and graphic displays in some plants on DCS (Distributed Control System) or

Data acquisition system, which in essence are Programmable Computers. The signals also are

provided for annunciators, which alarm the operator to the alert and danger levels of the

respective process parameters so that suitable action may be taken to restore back the normal

conditions. The motors and other drives have continuous indications on the panel showing their

status of operation. In some areas/plants there are data acquisition systems, which use computer

displays, showing the active process graphics, trending, and alarm summary displays, all on real

time basis. Also it gives historical trending and archives, which give the data storage for days

together. These computers are capable of giving the shift report and daily reports as desired by

the operational requirement. A large array of data helps in obtaining plant efficiencies, loading

capabilities, desired capacity levels, optimization and other flexibility as required for higher order

data management.

Continuous Automatic Process Control

Process Coordinators with artificial intelligence of pneumatic and electronic origin are used to

automatically control the process parameters under closed loop basis. Accordingly the operator

sets desired set point where the process parameters should be resident. The Coordinator

automatically controls the process parameters to keep the measurements coinciding with the set

point set by the operator. Momentary deviations between set point and measurement valves are

immediately controlled from the control algorithms processed automatically by Coordinators. The

Coordinator commands the actuating element mostly control valve which actuate the process to






maintain it at desired set point. The option of automatic and manual switch is provided in the

control station located in the control room. This control station serves as the man-machine

interface to the operator to decide if the particular parameter needs to be controlled either in

manual or in auto. While in auto the Coordinator takes charge of the parameter to control it

automatically and the manual mode serves the operator to control himself manually should he

desire to do so.

Process Analysis

The online process analysis is done through these analyzers who determine the chemical

compositions of the process. This helps in the basic processing of the intermediary and end

product and indirectly the efficiencies. The sensors for these analysers are strategically located at

different sections of the plant to enable the operator to analyse the process conditions. Alarms in

the monitoring of these analysers alert the operator of its threshold and danger levels so that any

limitations can be maneuvered to correct the process quality.

Emergency Shutdown Systems

To automatically determine the safety of the process equipment and manpower, the automatic

emergency shutdown system has been provided for each plant. The shutdown and safety devices

which consist of trip relays, solenoid valves, relief valves, safety valves, control valves,

programmable logic Coordinator will set and integrate to trip the plant/shutdown automatically or

manually on request, should there be any override of the process parameters, reaching to danger

levels. Every time before starting the plant, this shutdown trip system is tested by simulation to

check the health of the trip device, its response time, set values and its authenticity. The

emergency shutdown system has alarming functions to diagnose the cause of the trip and whether

a safe shutdown has taken place. The components of this system is most of the time duplicated to

provide redundancy and enhanced reliability so that it serves as a watchdog to guard the plant

from abnormal process parameter levels.

Quality Control Laboratory

The Laboratory is well equipped to provide detailed analysis of all the compositions as required by

the process. Its manpower works in rotational shifts round the clock and has a schedule of various

analysis which are to be carried out, offline on periodic time basis. In some plants, there are

facilities of automatic analyzer to analyse the composition of end product of some of the products

manufactured by the Company. Most of the instruments are of the latest microprocessor based

origin having very high fidelity and accuracy. Some of the instruments are gas chromatographs,

spectrophotometers, digital titrators, electronic balances, pH and conductivity monitors etc. Other

forms of analysis through reagents, titrations and dedicated reactions are carried out to determine

and counter-check various compositions. The complete data is logged through computers and

store in its database. The Laboratory operating personnel have fixed scheduled to give the process

data analysis of the respective plants at predetermined times to the plant operators.

Maintenance & Repair Work Procedures according to the Generally Recognised Rules

of Good Engineering Practices

The maintenance work in the continuous chemical process plants at ZACL may be classified under

disciplines namely Civil, Mechanical, Electrical and Instrumentation.

The maintenance work may be categorised in all the above disciplines as follows:

Day to day minor repair work in the running plants;

Preventive maintenance during the running of the plants;






Preventive Maintenance during plant shutdown;

Plant shutdown repairs;

Replacements of the equipment/machinery due to ageing and obsolescence;

Technical inspection of pipelines, vessels, rotating machines, based on the guidelines of the

standard practice;

Predictive condition based maintenance of various machinery’s;

Redesign and modifications for optimizations and prevention of recurring failures and

downtime;

Procurement of spares and update parts / machinery /equipment / instruments.

Monitoring of all these above activities is being followed through registrations in the computerized

maintenance management system (IMPACT). Also history of all maintenance work carried out,

which was previously maintained in history cards has been updated into IMPACT. The latest

methodology of computerized maintenance work is being used. This computerization helps to

update the data management of all the maintenance work and provides a ready reference guide to

plan the work in advance in an enhanced structured manner. Monitoring of individual equipment

as regards its maintenance is now being trended/recorded to facilitate the logistics towards

determining the health of the equipment.

Maintenance work followed under good engineering practices.

Day to Day Minor Repair Work in the Running Plants

This work is initiated by the operations on daily basis through the formats of work request and

safety permits. Proper isolations of the work area is being done in the presence of operation and

maintenance staff and once the isolations are confirmed by checking through various instruments

such as explosive meters, oxygen meters, CO/CO2/H2 meters etc. Work is being carried out under

the direct supervision of maintenance engineers. Once the work is completed and the units are

tested and found satisfactory to be taken in line/commission, through the same work permit,

maintenance engineers hand over the jobs done to the operation supervisors, who in turn put

back the units in operation.

Preventive Maintenance during the Running of the Plants

Preventive maintenance schedules in the standby equipment and in the equipment/ units/

instruments wherever possible is being carried out on time basis. This also includes LLF methods

(Look-Listen-Feel method) wherein operation staff / maintenance engineers/technicians make

regular rounds to check the leakage, the abnormality of sounds, the heat dissipations, optimum

lubrication oil levels and its make up, external vibrations. They thus obtain the first hand

knowledge of the performance of the plant equipment/instruments/machinery.

Preventive Maintenance during Plant Shutdown

During the shutdown of the plants or annual turnaround, checking the alignment of machinery,

testing and simulation of instrumentation, electrical equipment, periodic replacements of units

such as bearings, bushes etc., internal cleaning and servicing of equipment/machinery,

replacements of worn-out parts well in advance before a breakdown occurs, testing of foundations

of equipment and machines, calibration of instruments, emergency trip devices, checking of the

safety devices such as safety valves, relief valves etc. are the areas which are planned as a

shutdown activity during the plant shutdown. All the moving and rotating parts are being

lubricated, fresh lot of lubrication oils are replenished in order to render a trouble free service till

the next annual turnaround.






Plant Shutdown Repairs

The repair work based on the breakdowns or inspections done during the running condition of the

plants are being carried out during the shutdown in all the disciplines including Civil. Replacement

and repair of refractory of furnaces, repairs of vessels and pipelines, repairs of control valves,

instruments, repair of rotating machines, safety equipment, etc. are few examples where the work

is taken up during shutdowns. The isolation procedure of shutdown jobs during shutdown is the

same as that of the isolation procedure during running of the plant. Job permits are being

renewed in every shift and maintenance as well as operating personnel does monitoring.

Replacements of the equipment/machinery due to ageing and obsolescence

To enable the long term planning so as to keep the plant running for a long time, safeguards

against ageing and obsolescence is of utmost important and this is mostly being planned for

execution during plant shutdowns/ turnarounds. At times, detail engineering to redesign these

modifications is required to incorporate suitable alternatives due to the non-availability of spares,

so as the equipment/machinery is serviceable without sacrificing safety and good engineering

practices.

Technical inspection of pipelines, vessels, rotating machines, based on the guidelines

of standard practice

A separate section is in charge to check/inspect the quality of welding, the vessel internal

leakage’s, equipment internal deterioration, and to monitor the long-term health prospects of the

equipment. All the fresh weld joints are tested/ X-rayed as per the standard procedures.

Recommendations for the type of materials and a constant pursuit to incorporate better materials

are supervised by this section. This work is being carried during the breakdowns or annual

turnaround, or during the running of the plants. Internal testing of the exchangers or peel-off of

vessel linings, or internal material erosions are another areas where this section plans and advises

to other sections for the repair activities if necessary.

Predictive maintenance of various machinery

All rotating machines of different types are undergoing online and off-line predictive monitoring to

determine its performance on continuous basis. This monitoring includes vibration, axial thrust,

eccentricity analysis, check of bearings through shock pulse methods, orbit analysis to determine

the alignment of shafts are some of the areas where the dedicated team under equipment section

is continuously monitoring on off-line basis. All the daily readings are tabulated and computerised

and various trends are drawn to manage the data and provide signals, which can alert the

maintenance and the operation. The on-line predictive monitoring consists of sensors which

continuously monitor the parameters such as vibration, axial thrust displacements etc. and provide

a direct on-line recording. This helps in triggering signals to alert the plant operators and trip the

plants in case of emergencies.

Redesign and Modification for Optimization and Prevention of Recurring Failures and

Downtime

These are the backup services for maintenance which give a continuous feed backs of the latest

developments so that it can be incorporated in the existing system to keep the equipment/

machinery updated with the latest technology. It also helps to eliminate the long-term

shortcomings in the older designs and look for upgrading the plant efficiencies and energy

savings. Its work is of project nature, mostly to be done or hooked up during shutdowns. The job






involves design, detail engineering, procurement, erection/installation and commissioning and is

undertaken by Maintenance Department.

Procurement of spares and updated parts /machinery /equipment /instruments

Planning for the complete maintenance work, its spares, replacements, and redesigns wherever

necessary is a continuous activity, which is being planned in anticipation to the actual maintenance

needs for the plant use.

7.2.19 Emergency Control Procedures

Evacuation Procedure

In case of any emergency, evacuation of the personnel is very essential. We have identified 12

Assembly Points where the personnel have to assemble. All these Assembly Points are in charge of

persons who will be responsible for doing Head count and shifting them to a safer place.

The Welfare Coordinator along with Security coordinator shall be the Key Persons who are in

charge of evacuation. If required, they may take assistance from the other persons reporting to

ECC. For evacuation of the plant personnel, two routes are identified which shall be used

depending upon the wind direction.

Main Gate House

DAP gate (Materials Gate)

List of vehicles which will be made available for transporting people in case evacuation is required

is as follows:

Type of vehicle No. of vehicles Contact No

Buses 5 9850035599, 9765376438

Light motor vehicle 8 9921853500, 9762476107, 9823157833

The company owned cars and personal cars of the employees if required can also be used for

evacuation.

Medical Emergency Procedure

The affected persons will be provided first aid and then transported with available means of

transport to the Health Centre. Once the casualties arrive at Health Centre, Medical Coordinator

will examine and decide upon sending them to the pre-identified hospitals. It is the responsibility

of the Medical Coordinator to inform the Over-all in Charge about the condition of the injured.

Restoration of Normalcy

After confirmation from all the coordinator that the emergency is controlled and in consultation

with the Over-all in Charge, the Chief Coordinator will authorize to sound “ALL CLEAR”.

Once the “ALL CLEAR” is sounded, it is indication that the emergency is over;

All external agencies like District Collector, Inspectorate of Factories & Boilers, and Police will

be informed by the Overall in Charge regarding cessation of the emergency;

Overall in-charge informs to higher up about the end of emergency;

Each plant shall resume to the normal operation after assessing the situation and following

the laid down procedure of plant start-up.






Training and Emergency Drills

Training

All the key persons, the coordinator of the response team and other required persons in the plant

are trained on their role during emergency. The following are the some of the areas where the

persons will be made aware of.

Safe handling of hazardous chemicals;

Procedure to be followed in reporting emergency;

Siren and manual call points;

Usage of fire extinguishers;

Use of different types of PPE’s;

First aid;

Evacuation procedure;

Emergency drills.

The following types of exercises and drills will be conducted.

Wet drills : Once in a month

Full-scale drill : January and December

Plan Review and Updating

The plan will be reviewed and updated.

The shortcoming observed during conduct of table top exercises/ mock drills.

Any change of process, handling of new hazardous chemicals.

Change in coordinator, their contact numbers.

The updating of the plan would be the responsibility of In-charge of Fire & Safety Dept. The

updated Plan would circulated to the concerned after the same is approved by Chief General

Manager-Operations/Chief Manufacturing Officer.

Controlled copies

Each controlled copy of the plan will be serially numbered and then issued to the concerned

person. The details of the same will be documented by in-charge of Fire & Safety. It will be the

responsibility of the concerned person to send back the old copy/pages to Fire & Safety Dept.

7.2.20 Details of Communication Facilities Available during Emergency

Method of Reporting and Declaration of Emergency

Any person noticing a fire, explosion or release of hazardous material should shout 'FIRE’ or ‘HELP’

and attempt to control the incident. He/she should dial 101/111 (Fire Station/ECC) or break the

nearest Manual Call Point, which automatically alerts the fire station, and its nearest location. The

telephone number 101/111 at the Fire Station/ECC is manned round the clock.

He should inform the shift-in-charge of the affected plant, giving the location of incident, brief

description of the emergency. The shift-in-charge should confirm by repeating the message

back to caller to proper communication;

Fires station will then press the bell to call Panel Operator from Weigh Bridge and Fire &

Security Inspector from main gate;






Panel Operator will immediately contact the coordinators and the information will flow as per

the attached communication chart.

The Message must be Clear, Short and should Contain:

Identification of the speaker;

Brief Description of the incident;

Location incident;

Status and seriousness of the situation;

Actions taken;

Immediate assistance required.

Declaration of Emergency

Localized emergency

The emergency situation arising in any section of one particular area which is minor in nature can

be controlled within the affected section itself with the help of in-house resources available at site

and the fire department. such emergencies should be informed to the chief coordinator.

Such an emergency does not have the potential to cause serious injury or damage to

property/environment and the domino effect to the sections of the affected plant or near by

plants/areas.

Major emergency

The emergency which cannot be controlled locally and has the potential to develop into a major

emergency with a potential to cause serious injuries or damage to properly/environment within

the affected area or to the nearby areas should be considered as a major emergency needing

immediate action and this plan would need to be activated. Such emergency situations always

warrant mobilizing the necessary internal and external resources to handle the emergency and

mitigate it’s consequences.

Immediate Actions for Major Emergency

The senior most officer available at the site must immediately inform Chief Coordinator and

ECC about the escalation of emergency;

After receipt of the call, Chief Coordinator will rush to the incident site;

Chief Coordinator after assessing the situation, take appropriate action to control the situation

and if it is beyond his control, informs the Overall In-charge. Chief Coordinator will direct the

Fire & Safety Coordinator to initiate sounding of emergency siren who in turn will ensure

prompt/immediate action for sounding of siren;

Overall In-charge would get in touch with ECC;

The panel operator at ECC would inform GM-M, Health Centre, Main Gate House, CM-F&S,

DGM-M&S, CM-I&E;

Overall In-charge would then rush to ECC;

After assuming the position of Overall In-charge in ECC, he shall contact with other senior

members in the plant.

Procedure for Sounding the Emergency Siren

An emergency alarm switch is installed in the Emergency Control Centre (Fire Station) and also in

Ammonia Plant. The siren can be sounded with the actuation of an “Emergency Alarm Switch”.

Chief Coordinator will direct Fire & Safety Coordinator to initiate sounding of the emergency siren






from the ECC. The siren can also be sounded by the shift-in-charge only in case of an extreme

emergency.

The siren will be operated in the following modes.

Onsite Emergency Siren A wailing sound for two minutes (4 seconds “on” & 2.5 seconds “off”)

Off-site siren A wailing sound for 2.45 minutes (2.5 seconds “on” and 1 second “off”)

All Clear Siren A continuous sound for a period of two minutes

Action by emergency staff

Fire pump operation

We have a good net work of fire hydrant system all throughout the plant. The water pressure is

continuously maintained at 7.5 kg/cm2. Any drop in water pressure, the fire pumps will start

automatically.

Security

On hearing emergency siren or on information, the fire fighting team will report to the

incident site;

Control and monitor the traffic movement;

All hot jobs inside the plant to be stopped.

Trained Fire fighting staff

All the trained fire fighting staff from the non plant areas will report to the Emergency Control

Centre and assist the emergency team, if required.

First Aiders

The certified first aiders belonging to non-plant areas have to proceed to the Health Centre and

assist the medical team, if required.

Other personnel

All the personnel not directly involved in emergency operations should proceed to the designated

Assembly Points, if the same is ordered by the Overall in-charge.

Sequence of Actions after Declaration of Emergency

After declaration of emergency, overall in-charge instructs communication Coordinator to

inform nearby hospitals, Police Station and Mutual Aid Members. Chief Manager-Fire &

Safety/Manager will assist in these operations;

Maintenance team reports to the incident site, if needed;

Overall In-charge will keep contact with Chief Coordinator;

The other plan in-charges occupy their respective plant and follow the instructions from Chief

Coordinator/Overall in Charge;

Overall In-charge in consultation with the Chief Coordinator and other key personnel decides

whether to shutdown the plant.






Other Guidelines

Fire personnel

The fire personnel represent in ECC/Fire Station or other designated person will act as ECC

operator.

ECC operator

To receive all incoming calls;

To inform Health Centre, Chief Manager-Fire & Safety, Main gate house;

To keep record of all incoming calls;

To assist the Communication Coordinator/Overall In-charge in communications.

Communication of Emergency

The emergency will be communicated to all by sounding of Emergency Siren. The Chief

coordinator briefs the Overall In-charge about the status, likelihood to affect other plants. The

mode of communication will be public address system, walkie talkie sets, internal /external

telephones or messengers. The various channels of communication are as below:

External communication

1. If, required key personnel can be contacted by external telephones.

2. Communication to nearby communities

Overall In-charge through GM-HR establishes telephonic contact with the identified key

persons in the neighbouring communities.

3. Communication to local authorities

Overall In-charge will contact local authorities like District Collector, Dy. Collector, Police, Fire

Station, Chief Inspector of Factories & Boilers. through the Communication coordinator.

4. Designated person for interaction with media

Sr. Manager-CSR & PR would be the Company’s authorized spokesperson for interacting with

media (TV channels, newspaper, etc)

5. Procedure for notifying families of the injured person

The responsibility of communicating to the families would be of GM-HR.

6. Centralised reporting office

ECC would be the Centralised Reporting office during the emergency.






Details of Fire Fighting & Other Facilities

The fire protection system at ZACL consists of the following:

Fire water hydrants, water foam monitors with fire pump system;

Long range trolley mounted water foam monitor;

Portable fire extinguishers;

Fire vehicles (2 nos.) – Foam Tender & Water Mist Tender;

Emergency Response Vehicle;

Hydrocarbon/smoke detectors with alarm;

Manual call point system (break glass type).

List of firefighting Equipment & Others

S. No. Equipment Quantity

1 Fire hydrant

Single hydrant 45 nos.

Double hydrants 72 nos.

Fire escape risers 54 nos.

2 Water/foam capacity for fire fighting

Raw Water Pond 9687 M3

Water monitors tank farm area 6 nos.

Foam compound in foam tank 2800 lts.

3 Fire pumps

Diesel engine driven pump : 2 no’s, 410 m3/hr, head 88m

Electrically driven pump : 1 no., 410 m3/hr, head 88m

Jockey Electrically driven pump : 2 no’s, 50 m3/hr, head 88m

4 Smoke /Heat detectors

Ammonia Compressor house 8 no’s

DG Room 2 no’s

Product handling plant 8 no’s

Library 04 no’s

Safety Training Centre 04 no’s

Stores 11 no’s

Works Office 25 no’s

Health Centre 11 no’s

5 Manual Call points 17 no’s

6 Hoses

7.5 m length 2

15 m length 103

7 Fire extinguishers

Dry Chemical powder 5 Kg 20




Foam type 9 liters 55

Carbon dioxide 2 Kg capacity 5

Carbon dioxide 4.5 Kg capacity 61

Carbon dioxide 9 Kg 23







8 Foam tender

Water tender 1 no

Water tank capacity 4000 lts.

Foam capacity 1000 lts.

Pump capacity 3000 lpm @ 7 kg/cm2

DCP 75 Kg (2 no’s)

9 Water Mist Tender 1 no.

Water tank capacity 2000 liters.

DCP vessel capacity 500 Kg.

Pump capacity 150 lpm @ 100 kg/cm2

10 Emergency Rescue vehicle 1 no.

Equipped with various types of items

11 Trailer mounted foam monitor 1 no.

Capacity 4500 lpm

12 Self Contained Breathing Apparatus 44 nos.

13 Chemical suits 14 nos.

14 Dewatering pump 1 no.

Capacity 700 lpm

15 Fire proximity suits 2 nos.

16 Compressor for filling breathing air 1 no.

List of other Safety Equipment


1 Trolley mounted long range breathing apparatus 3 nos.

2 Self contained breathing apparatus

Sets nos. Spare cylinder

45 minutes duration 24 -

30 minutes duration 20 17

3 Air line respirator 8 nos.

4 Canister gas masks

Ammonia 13 no’s

Urea 9 no’s

Utilities 10 no’s

NPK-A 8 no’s

NPK-B 7 no’s

RMH 4 no’s

DAP Gate house 5 no’s

Laboratory 2 no’s

Detecting Instruments

Plant Measuring Components

Ammonia LEL, O2, CO

Urea NH3

Urea O2

NPK-A NH3






Plant Measuring Components

NPK-B LEL, O2

Power Plant LEL, O2

Laboratory LEL, O2, CO

Fire Station LEL, O2

Wind direction indicators

Wind directors have been provided at various locations which are as under:

Old Horton sphere : 1 no.

New Horton sphere : 1 no.

Chlorine handling area : 1 no.

In front of Health Centre : 1 no.

CO2 absorber : 1 no.

RMH office : 1 no.

Details of First AID & Hospital Services Available & It’s Adequacy

Medical Arrangements

On receipt of emergency call ambulance will be immediately sent to the emergency site. First

aiders of the affected plant shall assist the emergency team at the site immediately and

subsequently the medical team at health centre. First aiders of non affected plant may be called to

assist the medical team depending on the number of the casualties. List of trained first aiders is

appended.

Medical officer (in his absence male nurse on duty) will act as medical coordinator. He will guide

the first aiders and the medical team. The Doctor will coordinate with chief coordinator. After

giving the first aid the casualty would be referred to higher medical care centre or detained at

health centre depending on the nature and severity of the trauma.

Health Centre

Occupational health centre situated inside the factory premises operates round the clock with

following facilities:

S. No. Manpower Number

1 Resident Doctor 1

2 Visiting Doctor 1 (Retainer)

3 Nursing Staff 4

4 First Aiders 50

S. No. Equipment Number

1 Ambulance 01

2 Beds 04

3 Oxygen Cylinders 02+02

4 Oxygenators 02

5 Stretchers 04

6 ECG 01

7 Glucometer 01

8 Nebulizer 01

9 Casualty Tables 02






Ambulance

There is an ambulance stationed at health centre round the clock. Whenever there is an

emergency ambulance is sent to the site and with the help of first aiders/rescuers the casualty is

brought to the health centre. If the person is serious he is referred to hospitals after giving first

aid for further management.

List of Emergency Medicines at Health Centre

S.

No. Emergency medicine

S.


S.


1 Inj Atropine. 18 I V Fluids. 35 Tab Vertin.

2 Inj Adrenaline. 19 Inj Tramadol. 36 Tab Valium 2.

3 Inj Rabipur. 20 Inj Calmpose. 37 Tab Trika 0.25.

4 Inj Tetanus Toxoid. 21 Inj Eptoin. 38 Tab Digine.

5 Inj Avil. 22 Inj Dolokind Aqua. 39 Tab Calpol/Crocin.

6 Inj Dexona. 23 Tab Sorbitrate. 40 Tab Lostat.

7 Inj Voveran. 24 Tab Avil. 41 Tab Stamlo.

8 Inj Reglan. 25 Tab Combiflam. 42 Tab Meftal Spas.

9 Inj Phenargan. 26 Tab Diclogesic. 43 Tab Mobizox.

10 Inj Gentamycin. 27 Tab Lasix. 44 Tab Bidanzen Forte.

11 Inj Stemitil. 28 Tab Atenolol 45 Tab Flexon Mr.

12 Inj Lasix. 29 Tab Enam. 46 Eye Wash Cups.

13 Inj Deriphyline. 30 Tab Telmisat. 47 Silverex Cream

14 Inj Betropose. 31 Tab Ecosprin. 48 Ryele’s Tube.

15 Inj Ranitidine. 32 Tab Clopitab. 49 Foley’s Catheter.

16 Inj Cyclopam. 33 Tab Depin. 50 Eye/Ear Drops

17 Inj 25% Dextrose 34 Tab Cardace

Facilities Available

Consultation;

Emergency handling;

Suturing facility;

Medical examination;

Transportation to referral centers.

Multiple Casualties Handling

In the event of a disaster involving multiple casualties, help of nearby hospitals/ doctors and their

paramedical staff would be available. The Company doctor shall arrange such help from the

outside whenever required. The list of such hospitals is given below:

List of Hospitals –Govt & Private

S. No. Name & location Type Beds Phone no.

1 Primary Health Centre, Cansaulim Govt. 12 2754036

2 Primary Health Centre, Cortalim Govt. - 2550274

3 Cottage Hospital, Chicalim Govt. 60 2540864

4 SMRC, Chicalim Private 100 6691919

5 MPT Hospital, Semi Govt. 100 2594931

6 INHS, Jeevanti, Vasco Govt. 79 2501233, 2501022






S. No. Name & location Type Beds Phone no.

7 Talaulikar Hospital, Vasco Private 22 2513456

8 Dr. Kamat Nursing Home, Vasco Private 12 2512354

9 Dr. Pai Hospital, Vasco Private 25 2513641, 2511899

10 Sanjeevani Hospital, Baina Private 39 2510024

11 Raj Tara Hospital, Vasco Private 8 2514883

12 Dr. Mesquita Maternity & Eye Hospital, Vasco Private 14 2513696

11 Vasco Clinic, Vasco Private 11 2513164

12 Goa Medical College Govt. 955 2458700

13 Dr. Parulekar Nursing Home, Baina Private 25 2513672

List of Employees Trained in First AID

S. No. EPR Section Section Tel. no.

1 2339 Sarvesh Karapurkar Utilities Plant 2690

2 2420 Gauresh Arondekar Laboratory 2653

3 2421 Rupesh Kotharkar Laboratory 2653

4 2423 Seby Barreto Utilities 2690

5 2426 Nitesh Nadkarni NPK-B maintenance 2332

6 2447 Hanumant Bykod Ammonia Plant 2670

7 2448 Suraj Chodankar Ammonia Plant 2670

8 2449 Savel Selveira Urea Plant 2661

9 2442 Manesh Naik NPK-B Plant 2660

10 2454 Gladwin Gonsalves Ammonia Plant 2670

11 2456 Samarth Tendulkar NPK-A Plant 2685

12 2434 Amresh Sawal Fire & Safety 2622

13 2467 Preetesh Prabhu Urea Plant 2661

14 2463 Rahul Gurav NPK-B plant 2660

15 2464 Arjun Kattimani Utilities Plant 2690

16 2466 Clive Lobo Laboratory 2653

17 2465 Aditya Kalangutkar Utilities 2690

18 2457 Satish Vaghmare NPK-A Plant 2685

19 80001 Armildo Dias Utilities Plant 2690

20 80003 Utkarsh U Laad Ammonia Plant 2670

21 80004 Roland F.Pereira Ammonia Plant 2670

22 80005 Dattaram M Sawant Ammonia Plant 2670

23 80006 Bhaskar M Naik Ammonia Plant 2670

24 80007 Akshay Naik Urea Plant 2661

25 80008 Manu Krishnan Ammonia Plant 2670

26 80009 Jayant G Kopardekar Utilities Plant 2690

27 80002 Minanath Mandrekar Laboratory 2653

28 80012 Audhut Parker NPK-A 2686

29 2495 Sarvesh G. Naik Instruments 2547

30 2504 Siddhesh Mhalsekar Civil 2618

31 2515 Avinash Bhargav Technical Services 2591

32 2514 Kishor J. Urea Plant 2661

33 2516 Santhosha Ammonia Plant 2670






S. No. EPR Section Section Tel. no.

34 2517 Nishanth Gowda R.S. Ammonia Plant 2670

35 2510 Reuben Anthony Torcato Inspection 2638

36 2508 L. Ramesh Babu Ammonia Plant 2670

37 2513 Kanakava Roy Instruments 2547

List of Employees Trained in Fire Fighting

S. No. EPR Name Plant /Section Tel. No.

1 2036 Prashant Salvi Utilities 2690

2 2351 Sankalp Kulkarni Technical Services 2591

3 2448 Suraj Chodankar Ammonia 2670

4 2508 Ramesh Babu Ammonia 2570

5 80008 Manu Krishnan Ammonia 2670

6 2083 Akash Valke Urea 2661

7 80007 Akshay Lobhanand Naik Urea 2661

8 2457 Satish Vaghmare NPK-A 2685

9 2422 Manesh Govind Naik Utilities 2660

10 2086 Vivek Mayenkar Product Handling 2586

11 2068 C.L.A. Fernandes Mechanical 2332

12 2510 Reuben Anthony Torcato Inspection 2638

13 2378 Ramesh Meti Mechanical 2452

14 2345 Saurabh Bandodker Electrical 2584

15 1566 Savio Barreto Electrical 2451

16 2340 Jayant Nirmalker Instruments 2547

17 2280 Chandresh Chari Mechanical 2480

18 2386 Aditya Kuttikar Laboratory 2653

19 2277 Anup Madkaikar Inspection 2638

7.3 OCCUPATIONAL HEALTH

Details of workers health of ZACL is given as below:

M/S. ZUARI AGRO CHEMICALS LTD. EIA & EMP FOR CUSTOMIZED NPK FERTILIZERS UNIT, GT, HRSG,

AAST & UREA GRANULATION UNIT CH-7: ADDITIONAL STUDIES


Health Status of Workers, ZACL




ECG Report






Audiometry Report






Health Check-up Report






List of W/C & Urinals in Factory Premises

S.

No LOCATION

GENTS

W/C

LADIES

W/C URINALS

1 FIRE STATION 1 0 1

2 DOCUMENTATION/KNOWLEDGE CENTRE 1 1 0

3 WORKS OFFICE 3 1 2

4 WORKS CANTEEN 1 1 2

5 MAIN GATE 1 0 1

6 HEALTH CENTRE 1 0 0

7 STORES 2 0 2

8 MAINTENANCE WORKSHOP 2 0 2






S.

No LOCATION

GENTS

W/C

LADIES

W/C URINALS

9 MAINTENANCE OFFICE 1 1 2

10 INSTRUMENT WORKSHOP 2 0 2

11 ELECTRICAL WORKSHOP 1 0 0

12 LABORATORY 2 1 0

13 WATER TREATMENT PLANT 2 0 0

14 LABOUR TOILET NEAR WTP 1 0 0

15 AMMONIA/UTY/UREA MAINT OFFICE 3 0 4

16 POWER PLANT CONTROL ROOM 2 0 1

17 DG CONTROL ROOM 1 0 1

18 DAP GATE SECURITY OFFICE 1 0 0

19 CONTRACTOR`S LABOUR TOILETS 2 2 1

20 AUTO WORKSHOP 1 0 3

21 NPK LABOUR TOILET 1 0 2

22 NPK -A CHANGE ROOM 2 0 1

23 NPK-B CHANGE ROOM 2 0 1

24 NPK-B LABOUR TOILET 2 0 2

25 UREA MAINT OFFICE 0 0 1

26 AMMONIA/UREA CONTROL ROOM 3 0 3

27 DAP-PH LABOUR TOILET 2 0 4

28 PH LABOUR TOILET 4 0 5

29 PH MAINT OFFICE 1 0 2

30 UREA PACKER SCALE LABOUR TOILET 1 0 0

31 NPK PACKER SCALE LABOUR TOILET 1 0 0

32 LABOUR CANTEEN 1 1 2

33 NPK-DAP MAINT OFFICE 2 0 2

34 AUTO LABORATORY 1 0 0

35 RAILWAY SIDING (UREA/DAP SIDE) 2 0 2

36 RAILWAY SIDING MARKETING OFFICE 3 0 1

37 RAILWAY SIDING LABOUR TOILET below Mkt office 1 0 1

38 EFFLUENT RECYCLE PLANT 1 0 0

39 SULPHURIC ACID U/L STATION 1 0 0

40 EXCISE OFFICE & CHANGE ROOM 2 0 0

41 LABOUR TIOILET NEAR NEW KCL SILO 4 0 2

42 CONTRACTORS FABRICATION YARD 0 0 3

43 CSO 1 0 0

44 PH-NEHA OFFICE 1 0 1

45 DAP GATE MARKETING/ LOGISTIC OFFICE 1 0 1

46 PH- CONTROL ROOM 1 0 2

TOTAL 71 8 62






7.4 EHS POLICY OF ZUARI AGRO CHEMICALS LIMITED

“annexure- document of risk...

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