application for terms of reference - welcome...

SEPTEMBER, 2017

APPLICATION FOR TERMS OF REFERENCE

OF

BRAKE LINING MANUFACTURING PLANT

AT

PLOT NO. 05, SECTOR- 7, IMT MANESAR, GURGAON

BY

M/s AA Friction Materials Pvt. Ltd.

(Registered Address: Flat no. 104,929/1, Naiwala, Faiz Road, Karol Bagh, New Delhi - 110005)

SCHEDULE AS PER EIA NOTIFICATION: 4(c) Cat. A

PLOT AREA: 4050 sqm

PROPOSED CAPCITY: Two-Wheeler – 6,67,000 Pcs/day

Commercial Vehicle –5,400 Pcs/day

M/s PERFACT ENVIRO SOLUTIONS PVT. LTD.

(NABET Registered List of Accredited Consultant Organizations

/ 8th August 2017/Rev. 56/Sr. No. 114)

5th Floor, NN Mall, Mangalam Palace

Sector 3, Rohini, New Delhi

Email: [email protected]

Phone No.: 011-49281360

Fax: 011-47528434

Brake Lining Manufacturing Plant at Plot No. 05, Sector- 7, IMT Manesar, Gurgaon by M/s AA friction Materials Pvt. Ltd.

1

ENCLOSURE: 1- PRE-FEASIBILITY REPORT ......................................................................................................... 2

1.1.1 Profile of promoter ................................................................................................................................ 4

1.1.2 Need of the Project ............................................................................................................................... 4

1.2 PROJECT DESCRIPTION ................................................................................................................................. 4

1.2.1 Project Details ....................................................................................................................................... 4

1.2.2 Land Area Details .................................................................................................................................. 5

1.2.3 The Google Image of Project Site .......................................................................................................... 6

1.2.4 10 Km Buffer Zone Map ........................................................................................................................ 7

1.2.5 Layout Plan ........................................................................................................................................... 8

1.2.6 Project Description with Process Details ............................................................................................... 8

1.2.7 Raw Materials with daily requirement .................................................................................................. 9

1.2.8 Manufacturing process ......................................................................................................................... 9

1.2.9 Machinery ........................................................................................................................................... 10

1.3 ENVIRONMENT MANAGEMENT .......................................................................................................................... 11

1.3.1 Manpower ........................................................................................................................................... 11

1.3.2 Water Management ........................................................................................................................... 11

1.3.3 Waste Generation and Management ................................................................................................. 14

1.3.4 Air Emissions and Control.................................................................................................................... 15

1.3.5 Power Requirement Source & Back-up ............................................................................................... 15

1.3.6 Noise Pollution Management ............................................................................................................. 16

1.3.7 Safety .................................................................................................................................................. 16

1.4 LAND DETAILS ............................................................................................................................................. 19

1.4.1 Land Form & Land Use ........................................................................................................................ 19

1.4.2 Existing Infrastructure around the Site ............................................................................................... 19

1.4.3 Proposed Infrastructure ...................................................................................................................... 20

1.5 PROJECT SCHEDULE AND COST ESTIMATES ................................................................................................ 22

1.5.1 Likely Date of Start of Construction and Completion .......................................................................... 22

1.5.2 Estimated Project Cost ........................................................................................................................ 22

1.6 PROJECT BENEFITS ...................................................................................................................................... 22

ANNEXURE I:DISCLOSURE OF ENVIRONMENTAL CONSULTANT...................................................................... 23

ANNEXURE II: TOPOGRAPHICAL MAP ............................................................................................................ 25

ANNEXURE III:LAYOUT PLAN .......................................................................................................................... 26

ANNEXURE IV: LAND PAPERS ......................................................................................................................... 27


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ENCLOSURE: 1- PRE-FEASIBILITY REPORT


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Introduction of the project

The proposed project is engaged in brake lining for two wheelers and commercial vehicles. The

M/s AA Friction Materials Pvt. Ltd. has applied for Environmental Clearance of proposed

capacity Two-Wheeler- 6,67,000 PCS/day and Commercial Vehicle-5400 PCS/day. The

company proposes to set up the industry at IMT Manesar, Gurgaon, Haryana.

As the proposed industry involves Asbestos based products, the project falls under activity 4(c),

category- A as per the EIA Notification dated 14th September 2006.

Asbestos is naturally occurring hydrated mineral silicate that crystallizes in fibrous form.

Mineralogically, asbestos can be classified into two major groups, namely the Serpentine,

which includes the most abundant variety of asbestos that is Chrysotile and the Amphibole

which includes Amosite, Crocidolite, Actinolite, Anthophyllite and Termolite. Asbestos a name

that embraces a number of fibrous mineral silicates, has been used for its resistance to

combustion. Asbestos is used for the manufacture of variety of asbestos- based products

mainly as asbestos-cement (AC) sheets, AC pipes, brake shoes, brake linings, textiles and ropes.

Asbestos is also incorporated into friction materials like brake lining and clutch pads, jointing

and gaskets. Asbestos in air at work place is a major cause of adverse effects on the health of

industrial workers. Fibers embedded in the lung tissue over time may result in lung diseases

such as asbestosis, lung cancer, or mesothelioma.

The producing countries of Asbestos are Canada, Brazil and Kazakhstan. In the proposed unit

Asbestos shall be imported from Kazakhstan as per the requirement.

Brake linings are composed of a relatively soft but tough and heat-resistant material with a

high coefficient of dynamic friction (and ideally an identical coefficient of static friction)

typically mounted to a solid metal backing using high-temperature adhesives or rivets. The

complete assembly (including lining and backing) is then often called a brake pad or brake

shoe. The dynamic friction coefficient "µ" for most standard brake pads is usually in the range

of 0.35 to 0.42.

Since the lining is the portion of the braking system which converts the vehicle's kinetic

energy into heat, the lining must be capable of surviving high temperatures without excessive

https://en.wikipedia.org/wiki/Coefficient_of_friction

https://en.wikipedia.org/wiki/Friction

https://en.wikipedia.org/wiki/Adhesives

https://en.wikipedia.org/wiki/Brake_pad

https://en.wikipedia.org/wiki/Brake_shoe

https://en.wikipedia.org/wiki/Brake_shoe

https://en.wikipedia.org/wiki/Kinetic_energy

https://en.wikipedia.org/wiki/Kinetic_energy


4

wear (leading to frequent replacement) or outgassing (which causes brake fade, a decrease in

the stopping power of the brake).

1.1.1 Profile of promoter

AA FRICTION MATERIALS PVT LTD is a company Private incorporated on 30.07.2013. The

Certificate of incorporation bearing Corporate Identity Number (CIN)

U34300DL2013PTC256056. The registered office of the company is situated at Flat no.

104,929/1, Naiwala, Faiz Road, Karol Bagh, New Delhi-110005.

To carry on business as manufacturers of parts and accessories for motor vehicles and their

engines [brakes, gear boxes, axles, road wheels, suspension shock absorbers, radiators,

silencers, exhaust pipes, steering wheels, steering columns and steering boxes and other parts

and accessories n.e.c.

1.1.2 Need of the Project

Use of Vehicles has been growing steadily, therefore demand of the product is increased.

However, efficient unit is bound to be a success.

1.2 PROJECT DESCRIPTION

1.2.1 Project Details

S.No Particulars Details

1 Type of Industry Brake Lining Manufacturing Plant

3 Category 4(c), ‘A’

4 Location Plot no. 05, Sector – 7, IMT Manesar, Gurgaon

5 Land use at the project

site

Industrial

6 Plant Capacity Two-wheeler- 6,67,000 Pcs/day

Commercial Vehicle- 5,400 Pcs/day

7 Estimated Project Cost 9.5 Crore

https://en.wikipedia.org/wiki/Outgassing

https://en.wikipedia.org/wiki/Brake_fade


5

8 Population 260 250

9 Power Requirement 1110. 05 KW

10 D.G. Set back up 2 x 500 KVA

13 Air Pollution Control

System

Dust Collector, Wet Scrubber

14 Water Requirement 17.5 KLD

15 Waste water Discharge 9 KLD

1.2.2 Land Area Details

Particulars Total area % Area

Total Land Area 4050 sqm 100

Built up area 3107.68 sqm 76%

Ground Coverage 2429.98 60%

Green Belt &Open & Road Area 1620.02 40%


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1.2.3 The Google Image of Project Site


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1.2.4 10 Km Buffer Zone Map

Map is also attached as Annexure II


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1.2.5 Layout Plan

The layout map is additionally attached as Annexure III

1.2.6 Project Description with Process Details

AA friction Materials Pvt. Ltd. is installing Brake Lining Manufacturing Plant of capacity Two-

Wheeler – 6, 67,000 Pcs/day & Commercial – 5,400 Pcs/day


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1.2.7 Raw Materials with daily requirement

The raw materials for the unit used in the manufacturing process is given below:

Compound Quantity (Kg/day)

1. Asbestos 11,500

2. Resin 1300

3. Nitrile Butyl Rubber (NBR) 2500

4. Friction Dust 2600

5. Other 7600

Total 25,500 Kg/day

1.2.8 Manufacturing process

1. Compounding

In this operation, various chemicals, which are used in brake lining materials, are mixed in

proper ratio by weight.

2. Mixing

In this operation, the material is mixed with the help of mixing machine (rulla) to form

sheets of liner.

3. Performing:

In this operation, fixed quantity of mix is compressed in a performing die on a hydraulic

machine to make the biscuit of the brake lining.

4. Heat Molding:

In this operation, sheets liner is given to its final shape on hot molding machine with the

help of dies at a constant pressure, temperature.

5. Post Curing

In this operation, sheet is fed in box oven for curing purpose to increase the hardness of

sheets. At this process temperature remains 100 to 150 C.


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6. Slitting

In this operation, liner sheets cut in slits as per sizes required for Brake shoe.

7. ID Grinding

Purpose of this operation is to clean inner surface of the liner and to maintain thickness.

8. Edge Grinding

Arc length is maintained in this operation.

9. Final Inspection

At this stage, inspection and testing is carried out to ensure that defect free supply reaches

to the customer. It includes visual and dimensional inspections.

1.2.9 Machinery

List of Plant and Machinery to be installed:

Machinery

1. Mixer

2. Pre-forming Machine

3. Hot Molding Machine

4. Post Curring Machine

5. ID Grinding

6. Drilling Machine

7. Thermo Pack Heater

8. Oven

9. Wet Scrubber

10 Dust Collector

1.3 Environment Management

1.3.1 Manpower

During Construction phase: 100 nos. labour During Operation phase: No. of Employees

Particulars No. of People

Staff 50

Labours 200

1.3.2 Water Management

1.3.2.1 Water consumption & Source &Waste water generation

The process is a dry process, no water is required. However, water is needed for domestic use.

The source of water will be HSIIDC.

Fresh water requirement 17.5 KLD

Total water requirement 17.5 KLD

Total waste generation 9 KLD

Usage Population Factor in LPCD

Total Water requirement in KLD

Waste Water Discharge in KLD

Domestic

Staff 250 45 11

Visitor 10 15 1.5

Sub-Total 12.5 KLD 9 KLD

Process (Cooling Tower)

1 KLD Nil

Wet Scrubber 2 Nil

Gardening 1 Nil

Misc 1 Nil


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Total 260 17.5 KLD 9 KLD

1.3.2.2 WATER BALANCE

1.3.2.3 Rain water harvesting scheme

The main source of ground water recharging in the study area is rainwater, which infiltrates

into the ground through various lithological units present in the study area. 2 number of

rainwater harvesting pits shall be provided to recharge the ground water. The runoff from the

rooftop and storm water shall go to the recharge pits.

Scheme for Ground Water Recharging

The rainwater is diverted from the rooftop using rain water pipes to the surface / underground

drainage network. The entire campus is sub divided for recharging structures.

The rainwater is diverted into the desilting tank to remove inorganic impurities and the outflow

of the desilting tank is taken into the recharge well.

Desilting Tank

The desilting tanks are used to remove silt and other floating impurities from rainwater.

Desilting tank is like an ordinary container having provision for the inflow, outflow and

overflow. Apart from removing silt it holds the excess amount of water till it is soaked up by

the recharge structure. The bottom of tank will have unpaved surface (layers of coarse sand)


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to allow standing water to percolate into the soil. The rainwater collected in these desilting

chambers shall be utilized for horticulture.

Recharge well

The Recharge Well consist the pit size of with dia 2.6 m and effective depth of 3.0 m with of

18.90 mm PVC perforated pipe will be lowered in the middle of the boreholes and the pit will

be filled with gravel and pebbles consisting of boulders, gravel and coarse sand. The mouth of

the PVC pipe shall be protected to avoid silt getting into it. The depth of the bore will depend

on the soil condition/water strata. The schematic diagram is enclosed. It should be therefore

concluded that there is no significant impact on surface water quality & hydrology of the area.

The proposed rainwater-harvesting scheme will stabilize the groundwater table in the area.

DESIGN CRITERIA: SOIL QUALITY : Silt clay INFILTRATION RATE : 36 mm/hr PEAK HOURLY RAINFALL : 45 mm/hr NO. OF RAINWATER HARVESTING PITS : 2 No. SIZE OF PITS : 3m x 4m x 3m

➢ Rain water calculation:

S.No. Description of Area

Area Considered

(Sq. M)

Harvesting Factor /

Collection Efficiency per area

Retention time for capacity of

recharge tank(in

minutes) (Peak hourly: 45 mm/hr)

Total Volume of Water

Available for Rain Water Collection

(Cubic Mtrs) (Peak)

1 Water Available from Terraces of buildings and other roof-top surfaces

2429.98 0.85 15 30.9

GRAND TOTAL 2429.98 sqm

30.9 Cubic Mtrs

RAIN WATER HARVESTING DIAGRAM


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1.3.3 Waste Generation and Management

1.3.3.1 Municipal Solid Waste

1.3.3.2 Process Waste(Non-Hazardous)

Process Waste Quantity of generation, Kg/day

Disposal method

Recyclable (lining) 150 Kg/day Shall be reused after grinding of solid waste into powder.

Packaging Material 100 Kg/day To Recycler

Category Type of Waste Color of Bins

Disposal Method Total Waste (Kg/day)

Bio Degradable Organic Waste (Includes Food & Kitchen

Waste, Leaves etc.)

Green MSW site of IMT 27

Non-Biodegradable

Recyclable Waste (Includes Poly-bags, Plastic, metal, wood,

paper, glass, containers etc.)

Blue Authorized recycler

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Total 39 Kg/day


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1.3.3.3 Hazardous Waste

The hazardous waste generated is given below:

Solid Waste Quantity of generation,

kg/day approx.

Method of Disposal

Used Oil 14 l/month Authorized vendor

Friction Dust 500 Kg Particles of mix will be

collected through dust

collector and reused in

process.

1.3.4 Air Emissions and Control

Source of Air Pollution Mitigation Method

D.G. Set back up (2 x 500 KVA)

Stack height of 5m shall be provided

Raw Material Handling All the raw material shall be stored in covered place. Material Shall be handled in the area

with dust control system.

Mixing Process Mixing shall be done in mixer which shall have channelization of dust to dust collector (Bag

filter)

Heat Treatment The air emissions shall be channelized to scrubber

Grinding There will be dust generation during grinding for which suction hoods shall be provided to

channelize dust to dust collector

1.3.5 Power Requirement Source & Back-up

The power requirement of project is 1110.05 Kw. The power will be supply by Dakshin Haryana

Bijli Vitran Nigam.

Particulars Total

D.G. Set back up 2 x 500 KVA


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1.3.6 Noise Pollution Management

To reduce Ambient Noise level the following measures will be adopted --

➢ Noise generating units like manufacturing plant, DG sets etc. will be well insulated with

enclosed doors.

➢ Maintenance of vehicles and machinery will be done in a sustainable manner to ensure

best performance and less loss.

➢ Vehicle and people flow during shift changes shall be regulated by allowing exits in a

phased manner.

➢ Earmuffs will be used while running equipment’s of the plant having high noise.

➢ The green belt will help in reducing noise levels in the complex as a result of attenuation

of noise generated due to plant operations and transportation.

1.3.7 Safety

Safety in design and operations are therefore of paramount importance.

1.3.7.1 Safety in Design

Following are the strategies to improve the safety of the people and plant:

• Use of proven technologies and equipment

• Use of latest safety process know-how

• Modern risk assessment techniques to design effective safeguarding system for all

critical locations in the process

• Design plant in accordance with applicable codes and standards and maintain standard

engineering practices during detailed engineering

• Carryout extensive studies during the process design stage to ensure safety,

occupational health and environmental aspects are addressed in P& IDs, PFDs and

other engineering deliverables.

• Minimize presence of large hydro-carbon inventories by designing liquid hold up

volumes in vessels based on control and operational requirements

• Locate storage tanks in off-site area

• Pressure relief valves in all pressure vessels.

• Occupational Health

• Fixed detection system with alarms and data logging


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• Trained personnel made fully aware of the hazards of process and operations.

Personnel must also be informed of the health hazards

• Periodic refresher training

• Minimize unnecessary exposure to airborne contaminants and direct exposure to

chemical hazards

• Good housekeeping

• Emergency showers and eye wash facilities at appropriate locations

• Health surveillance programs

1.3.7.2 Safety in Operations

Person breathing the air may then inhale asbestos fibers. Continued exposure can increase the

amount of fibers deposited in the lung. Fibers embedded in the lung tissue over time may result

in lung diseases such as asbestosis, lung cancer or mesothelioma. It can take from 10 to 40

years or more for symptoms of an asbestos-related condition to appear.

A suitable organization shall be implemented to manage the safety of people and plant. The

organization shall be responsible for building and maintaining “a culture of safety” and shall

thrive to elevate safety to near religious levels. Suitable systems shall be designed and

implemented for safety training and awareness.

A suitable fire protection system with dedicated firewater network for the whole complex has

been designed and installed. Besides, facilities such as dedicated fire station equipped with

firefighting equipment such as fire tenders has been put up. A dedicated fire alarm system and

special arrangements to protect control rooms in case of fire has also been commissioned as

part of the project.

• Exposure to asbestos at the time of handling and transferring raw asbestos to and from

storage container to storage rooms. Gloves and mask shall be provided to the labours

at the time of handling.

• Exposure to the air of asbestos. Dust collector and wet scrubber shall be install for

preventing from exposure to air environment.

• Asbestos in air at work place is a major cause of adverse effects on the health of

industrial workers. Fibbers embedded in the lung tissue over time may result in lung


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diseases such as asbestosis, lung cancer, or mesothelioma. Quarterly check-up of the

labours will be done. Appropriate treatment shall be provided.

• Taking clothes inside the home or tracking dust through the house after performing

brake and clutch work to prevent exposing

• Exhaust dust collection system with HEPA filtration shall be install to dust exposures

and work area contamination.

• Low speed drilled, grooved, cut shall be used to keep down the amount of dust created.

Approach:

• Provision of air pollution control system to comply with the emission standard of 0.2

fibre/cc for asbestos fibre and 2 mg/Nm3 for total dust. Provision of interlocking of air

pollution control equipment with the manufacturing process should be provided.

• Engineering controls to comply the chrysotile asbestos fibre concentration at work

plane of 1 fibre/cc as per the provision of Factories Act.

• Provision of local exhaust ventilation systems (BIS code of practices IS 12080-1987

(Reaffirmed 2001))

• Cleaning should be done in accordance with the provisions laid as given in BIS code of

practice IS 11767-1986.


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1.4 LAND DETAILS

1.4.1 Land Form & Land Use

The project site is allotted for industrial development and site itself in IMT Manesar, so there

will be no change in land use, land cover or topography. There is a lease agreement between

M/s Aadinath Overseas LLP and AA Friction Materials Pvt. Ltd. for land area 4050 sqm and built-

up area 3107.68 sqm.

1.4.2 Existing Infrastructure around the Site

1.4.2.1 Routes or facilities used by the public for access:

Nearest Railway Station : Patli Railway Station- 6.65 Km NWW

Nearest Airport : IGI Airport, - 26.63 Km NW

Nearest Highway : NH-8 – 2.52 Km SEE


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1.4.2.2 Social Infrastructure:

Particular Distance

Hospital ESIC Hospital VPS Hospital Yashlok Medical Center Paras Medical Hospital Vijay Hospita Post Office Post Office Places of worship Radha Krishna Temple Shiv Mandir Sri Durga Mandir School / Colleges Laxmi International School Bal Bharti Public School Ompee World School Deepika Public School DPS Manesar Bank State Bank of India Union Bank of India Oriental Bank Of commerce Indian Bank Bank Of India

1.55 Km S 5.09 Km NE 3.37 Km SE 2.18 Km SSE 2.86 Km SE 3.13 Km SE 2.93 Km SE 2.91 Km SE 3.56 Km SE 2.09 Km S 2.96 Km SE 3.11 Km SE 3.16 Km SE 3.95 Km SE 1.18 km W 0.39 Km SSE 0.87 Km SW 1.93 Km SE 2.90 Km SE

1.4.3 Proposed Infrastructure

1.4.3.1 Processing Area

1.4.3.2 Green Belt

Green belt planning has been done as per guidelines laid by CPCB. With ecological perspectives

of the project availability of space and other aspects shall be considered. This will help in

increasing the aesthetic effect of the environment. Green belt/greenery will be developed

along most of the periphery of the project area as well as along roads.


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For green area, the trees planted will be of adequate height. Any tree that does not survive

will be replaced. Ornamental trees will also be planted to improve the aesthetic looks of the

project area. The following characteristics have been taken into consideration while selecting

plant species for green belt development and tree plantation.

• They shall be fast growing and tall trees.

• They shall be perennial and evergreen.

• They shall have thick canopy cover.

• They shall have large leaf area index.

Since tree trunks are devoid of foliage, scrub should form there to give coverage to the trunks.

The trees will maintain regional ecological balance and conform to soil and hydrological

conditions. Indigenous species would be preferred. Before planting of trees, seedlings,

saplings, grass species, shrubs, soil preparation, soil amendments etc are to be undertaken well

in advance. For proper survival and healthy growth of plant species a nursery is also

maintained at the site. It is ensured that proper density of plants is maintained at site. Post

plantation care is also necessary and maintained in planned and scientific manner.

1.4.3.3 Liquid Waste

9 KLD of domestic waste shall be generated in the industry which shall be discharge to the

sewer line of HSIIDC. Waste shall be treated in CETP of IMT Manesar.

1.4.3.4 Parking Facility

Adequate parking provision shall be provided on surface for trucks, two-wheeler and four-wheeler.

Also, separate loading & unloading area shall provide within the project premises.

1.4.3.5 Rehabilitation and resettlement Plan

There is no need for R&R activities for the activity.


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1.5 PROJECT SCHEDULE AND COST ESTIMATES

1.5.1 Likely Date of Start of Construction and Completion

Construction/Installation shall be started after getting Environmental Clearance and other

relevant approvals. The constructional installation of the unit will be completed within 7-8

months.

1.5.2 Estimated Project Cost

The estimated project cost is Rs. 9.5 Crores.

1.6 PROJECT BENEFITS

• The Proposed project is pollution free since there is no water discharge. So, it’s an eco-

friendly project.

• Use of Vehicles has been growing steadily and an efficient unit is bound to be a success.

• It will provide direct and indirect employment to local youth.

• The product Brake Lining shall be used in Commercial vehicles and two-wheeler, the

demand of which increasing day by day.

Economic Viability of the Project

Being a consumable item of automobile industry, there is a huge demand. Further, being safety

proprietary item, rates are such that the project is financial viable with ROI of 15% and above.


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ANNEXURE I:DISCLOSURE OF ENVIRONMENTAL CONSULTANT


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ANNEXURE II: TOPOGRAPHICAL MAP


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ANNEXURE III:LAYOUT PLAN


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ANNEXURE IV: LAND PAPERS

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