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$: CHAPTER 4 ENVIRONMENTAL IMPACT …gpcb.gov.in/pdf/SWANA_PHARMA_EIA_PART_2.pdfAkshar Consultants REIA OF SWANA PHARMACEUTICALS PVT. LTD., VIL. : VARSOLA, DIST.:KHEDA, GUJARAT. { 102$
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REIA OF SWANA PHARMACEUTICALS PVT. LTD., VIL. : VARSOLA, DIST.:KHEDA, GUJARAT.

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CHAPTER – 4

ENVIRONMENTAL

IMPACT ASSESSMENT

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Chapter - IV

Environmental Impact Assessment

4.1 Introduction

Environmental Impact Assessment (EIA) is a process or an endeavour

to identify, predict, assess and convey the probable environmental

impacts due to the project on various components of environment of

the surrounding area. Predicted impacts are then superimposed on

existing base-line status (pre-project) to make an effort to arrive at the

resultant environmental scenario after the project becomes operational

(post-project). Resultant post-project scenario is further evaluated

against the statutory environmental regulations applicable to the area

to find out if the post project scenario will be in conformity with the

requirements or not. Evaluation and prediction of environmental

impacts of the project also helps in developing a proper Environment

Management Plan (EMP) incorporating measures to mitigate negative

impacts and enhance positive impacts during project implementation

and operation phase.

Process of impact assessment basically includes :

• Identification of different project activities and their likely impacts.

• Categorisation of likely impacts based on nature (positive or negative,

direct or indirect), duration (short term or long term), magnitude

(negligible, moderate or severe), reversible or irreversible etc.

• Assessment of qualitative and quantitative aspect of the likely impacts.

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This chapter presents the identification, prediction and evaluation of

various impacts with mitigation measures of the proposed bulk-drug

manufacturing activity of SPPL at Plot No. 632, 633, Nadiad –

Mahemdabad Highway, Village – Varsola, Ta – Mahemdabad, Dist –

Kheda, Gujarat. Impacts are predicted considering that the impact of

existing sources of pollution has already been taken into account in the

baseline environmental status.

Prediction and evaluation of impact on components of environment i.e.

water, land, noise, flora-fauna etc. has been done using scientific

knowledge and judgment.

4.2 Impact Identification For the purpose of impact identification, the entire project has been

divided into two phases :

1. Pre - operational Phase ( construction and erection/commissioning )

2. Operational Phase

4.2.1 Construction and Commissioning Phase

As SPPL has complete infrastructure suitable for manufacturing of

proposed products, no major construction activity will be required to be

carried-out. Only minor civil work like foundation of new vessels etc.

will be carried-out. During commissioning, mechanical and electrical

erection of equipments / machineries will be carried-out. The broad

activities during this period will be as follows :

1) Foundation work only for new machinery.

2) Erection of only new mechanical equipments.

3) Synchronisation of various equipments / processes and final

commissioning of plant.

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Construction cum commissioning phase of the project will be for a

shorter duration as compared to operational phase.

Construction cum commissioning phase will mainly involve noise

pollution (erection of mechanical machineries etc.) and demand for

water (for domestic requirement of construction and commissioning

work force).

Though Aesthetics and Socio-economic factors are also identified,

the impacts related to the same will be marginal only.

Mostly, local man power will be used during this phase. Similarly, there

will be no displacement and rehabilitation of people due to this project.

4.2.2 Operational Phase Because of its’ potential to create long-term impacts, this phase is

very important from the environmental impact point of view. The basic

impacts like gaseous emissions, water consumption and solid waste

will have potential to adversely affect air, water and land / soil in the

vicinity of the project site.

This phase will broadly include following direct and indirect activities /

actions :

• Entire chain of activities related to production cycle.

• Storage and transportation of raw materials and finished

products.

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• Gaseous emissions

• Effluent Generation, treatment and disposal

• Noise Generation

• Solid waste generation

• General equipment failure

• Industrial development of secondary units in the area

• Greenbelt Development 4.3 Prediction And Assessment Of Impacts

Prediction and assessment of impacts during construction and commissioning phase and operational phase of the project is given below :

4.3.1 Construction and Commissioning Phase

4.3.1.1 Air Environment

Impact on air environment due to construction and commissioning

activities will be negligible as construction activity itself will be limited

to few foundations of new equipments. Thus, impact on SPM and

gaseous emission levels will be negligible during this period. Power for

construction cum commissioning work will be obtained through grid

power.

However, all efforts will be made to ensure that impact on air

environment is minimum. This will include :

Minor civil construction work will be carried out during day time.

Separate civil construction material storage yard will be created

within the site and it will be enclosed.

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4.3.1.2 Water Environment

Total water requirement for construction cum commissioning activities

is estimated to be approx. 2 cu. mt. per day. It will be met through

existing bore well.

Company has no plan to create temporary housing arrangement for

construction labourers at site as only minor civil work will be there. The

peak labour force during construction cum commissioning phase is

expected to be 10 persons. Only drinking water and other

miscellaneous requirement during day time for this work force will be

there which is estimated to be approx. 2 cu. mt. per day. This

requirement too will be met through existing bore-well.

Thus, construction and commissioning activities are not likely to have

any adverse impact on quality and availability of water in the

surrounding region.

4.3.1.3 Solid Waste

Remains of construction material like rubble, brick bats, debris, steel

scrap, wooden scrap, sand, gravel etc. are the only likely solid wastes

to be generated during minor construction activity of the project.

However, such solid wastes are inert in nature and will be collected and

utilised in filling of low lying areas within the premises of project site.

Wooden scrap, steel scrap will be given to scrap dealers.

Therefore, construction activities are likely to have no adverse impact

due to generation of solid wastes.

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4.3.1.4 Noise Environment

As a result of various activities like civil construction, erection,

movement of vehicles and installation of machinery etc., slight increase

in noise level is anticipated for a short period. However, all construction

and commissioning activities will take place during day time only and

consequently noise level is expected to go up during day time only.

4.3.1.5 Land Environment

As no major construction activity will take place, no significant change

to the topsoil of the project area due to excavation, stacking of

construction material etc. is anticipated. Also, no impact on land

outside the premises will be there due to construction activity.

4.3.1.6 Ecology

The components that are identified to describe ecology are animals,

birds, fish, field crops, threatened species, natural vegetation etc. The

area where SPPL unit is located does not have any Forest, National

Park, Sanctuaries etc. and hence there is no question of impact on the

same.

Since the construction and commissioning activity will be very limited

and restricted to the existing site only, no change in local ecosystem is

anticipated because of this project of bulk – drug manufacturing.

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4.3.1.7 Socio – Economic Pattern

The construction and commissioning phase of the proposed bulk – drug

manufacturing project is likely to have certain positive and negative impacts

on socio-economic environment.

Setting up of project at the said site does not require displacement of

any population. Local people involved during construction and

commissioning work will have benefit of temporary employment.

However, there will be pressure of additional traffic on State Highway

No. 3 due to movement of vehicles for construction material and

equipments. But it will be very minor impact for a very short duration.

4.3.1.8 Health and Safety

No health and safety problem of surrounding population is anticipated due to

construction and commissioning activities of the proposed project.

No health problems of labour force are anticipated as there will be no labour

force staying at site.

SAFETY

All safety measures will be incorporated during the construction and

commissioning phase to ensure full safety of work-force and workers

will be made aware of the safety requirements and asked to strictly

follow the safety norms.

4.3.1.9 Aesthetics

Construction activities will contribute to some deterioration of site

aesthetics. However, it will be restricted to site only. Aesthetic value of

the site will be restored after civil work is over.

Various impacts of construction phase alongwith their characteristics

are summarized in TABLE NO. – 4.1.

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TABLE NO. 4.1

IMPACT MATRIX FOR CONSTRUCTION PHASE Activity Construction Construction Movement of Gaseous Solid Green Materials Activities Transportation Emissions Waste Belt Storage & Vehicles generation Development Parameter Handling Air Negligible Negligible -ve, ST -ve ST No Impact +ve, LT Water No Impact Negligible No Impact No Impact No Impact +ve, LT Noise -ve, ST -ve, ST -ve, ST No Impact No Impact +ve, LT Odour No Impact No Impact No Impact No Impact No Impact +ve, LT Flora No Impact No Impact No Impact No Impact No Impact +ve, LT Fauna No Impact No Impact No Impact No Impact No Impact +ve, LT Soil -ve, ST -ve, ST No Impact No Impact Negligible +ve, LT Forest No Impact No Impact No Impact No Impact No Impact No ImpactReligious / Historical Places

No Impact No Impact No Impact No Impact No Impact No Impact

Population +ve, ST +ve, ST -ve, ST Negligible No Impact +ve, LT Socio-economic +ve, ST +ve, ST No Impact No Impact No Impact No ImpactCultural No Impact No Impact No Impact No Impact No Impact No ImpactHealth and Safety Negligible -ve, ST -ve, ST Negligible No Impact +ve, LT Aesthetics -ve, ST -ve, ST No Impact No Impact No Impact +ve, LT

+ ve – Positive (beneficial) ST – Short Term - ve – Negative (adverse) LT – Long Term Negligible - Negligible Impact

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4.3.2 Operational Phase 4.3.2.1 Air Environment

Base line data reveals that ambient air quality in the study area for the

parameters PM2.5, PM10, SO2, NO2 & HCl is well within the permissible

limits as prescribed by the National Ambient Air Quality Standards

(NAAQ) for Industrial Area, Residential, Rural & Other area.

Emission of PM, SO2 & NO2 from stacks attached to non-IBR baby

boilers and Incinerator and HCl emission from scrubber attached to

process vent will form the only source of air pollution.

As the unit is an existing unit manufacturing 3, 2, Gunidino Thiozol 4,

Methyl Thiopropionitrile base, it has two nos. of non-IBR baby steam

boilers, one no. of liquid incinerator and one no. of process scrubber

already working in the premises. For manufacture of proposed bulk-

drag products, no additional stack will be provided. Same steam

boilers, liquid incinerator and process scrubber will be used for bulk-

drug manufacturing also and also for same duration of time per day.

Unit will discontinue manufacturing of existing product and in its’ place

the proposed bulk-drugs are to be manufactured.

Operational parameters of all the stacks and pollutants to be emitted

alongwith their concentration will also remain the same as in case of

existing products.

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Thus, no. of pollutants, their emission rate and total emission for

proposed products will be the same as no. of pollutants, their emission

rate and total emission taking place right now for existing products. And

since the existing air emission from the plant is already reflected in the

background air quality of the study area, no separate calculation of

GLC of various pollutants has been carried out for this project.

4.3.2.2 Water Environment QUANTITY OF WATER CONSUMPTION

The quantity of water required for the domestic use for the project is

about 2.0 m3 / day.

The quantity of fresh water required for the industrial use of the

project will be about 9.5 m3 / day.

The quantity of fresh water required for the gardening purpose of the

project is about 10 m3 / day.

Thus, maximum requirement of raw water for the project will be about

21.5 m3 / day in totality.

Thus, there will be impact on the surrounding water environment due to

the water used for various purposes. It may be noted that existing

water requirement of the unit is around 17.5 m3/day and hence, net

increase in water requirement for proposed new products will be only

4.0 m3/day. However, it will be effectively mitigated by a water

recharging scheme which has been outlined in detail in ANNEXURE –

12. Thus, there will be no negative impact on the ground water

availability of the area due to manufacture of new products.

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QUALITY OF WATER CONSUMED

Baseline data indicates that in the study area, quality of water is

satisfactory to serve for domestic purposes as per Standards

prescribed by the IS : 10500 for drinking water.

QUANTITY OF WASTE WATER GENERATION AND DISPOSAL

Quantity of domestic effluent generated after the operation of the


Quantity of industrial effluent generated after the operation of the


QUALITY OF WASTE WATER AND DISPOSAL

All the effluent streams :

Process and washing effluent ( approx. 1.50 KL per day ) Softening plant regeneration water ( approx. 1.00 KL per day ) Cooling tower blow – down effluent ( approx. 0.50 KL per day ) Scrub liquor effluent ( approx. 0.50 KL per day )

will be given in-house treatment in the existing effluent treatment plant (ETP)

of SPPL which consists of primary treatment units (mainly collection cum

neutralization tank). Total effluent quantity will then be incinerated in the in-

house existing incinerator which has a capacity to incinerate 250 Liters of

effluent per hour.

Domestic sewage will be disposed off through septic-tank / soak pit

system.

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Thus, it can be concluded that there will be insignificant adverse impact

on the surrounding environment as it will be a “Zero Discharge out side

premises “ unit.

4.3.2.3 Solid Waste

Details of anticipated solid / hazardous waste generation from the project are

given below.

HAZARDOUS WASTES FROM THE PROJECT

Sr. No.

Description of Solid Waste

Quantity per month (in MT)

Method of collection

1. Spent Carbon / Hyflow from process

0.50 In polythene bags.

2. ETP sludge 1.00 (on dry basis)

-- do --

3. Incineration Ash 1.80 -- do --

4. Discarded drums / containers

50 Nos. --

5. Used oil 0.15 KL In 200 Ltr. Barrel

6. Solvent residue 2.00 - do -

Hazardous wastes will be disposed in following manner :

used oil will be given to CPCB registered recycler / re-processor of oil.

Solvent residue will be given to common incineration facility of BEIL at Bharuch, Gujarat or will be incinerated in-house.

ETP sludge and spent Carbon / Hyflow / Sodium Sulphate etc. will

be disposed off into TSDF of NEPL at Ahmedabad.

Discarded containers after decontamination will be given to registered vendor.

Proper monthly records of generation, storage & disposal of hazardous

waste will be maintained in a register as per the format of Form – 3 of

Hazardous Waste (M, H & T M) Rules – 2008. Annual returns of the

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disposal of wastes in Form – 4 and Form – 13 (manifests) will be

submitted regularly to the local office.

Thus, it can be concluded that there will be no impact on the

surrounding environment due to generation and disposal of solid waste

during operation phase of the project.

4.3.2.4 Noise Environment

Noise levels in the ambient air are well within the permissible limits

given by the National Ambient Noise Level Standards as confirmed

during base line study. The Leq values of the noise levels within the

plant premises will be kept less than 75 – 70 dB(A) ( during day time

and night time ) which will be within the permissible limit.

Areas where continuous presence of worker is required, workers will be

provided with earplugs.

The major sources of noise from the proposed project will be vehicular

movement, loading – unloading and transfer of material, operation of

various equipments etc.

Development of Green Belt in and around the plant campus helps in

reduction of noise. As already stated, sufficient ear-protecting devices

will be provided to personnel working in high noise generating areas.

Hence, it is unlikely that there will be practically any increase in the

background noise level beyond plant boundary during operation phase

of the project.

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4.3.2.5 Land Environment

Soil is affected by impact of release of air pollutants, effluent disposal

and solid waste disposal. However, as explained in point no. 4.3.2.1

above, there will be no net increase in air pollution due to proposed

bulk – drug manufacturing and gaseous emissions from stacks

attached to non-IBR baby boilers, incinerator and vents attached to

scrubbers will be within the norms. Moreover, vents of proper height

have been provided for quick dispersion and dilution of pollutants into

the air. Thus, there will be no additional effect on the surrounding soil

due to gaseous emission from the project.

There will be no major effect of wastewater on soil as all the

wastewater generated will be incinerated in the in-house incinerator.

The domestic wastewater will be disposed off through septic tank /

soak pit system. Thus, there will be practically very insignificant impact

on land due to disposal of wastewater.

All necessary control steps for each type of Solid Wastes generated will

be taken, and hence there will be no impact of solid wastes generation

on surrounding soil environment.

4.3.2.6 Ecology

Air emissions, liquid effluent disposal and solid waste generation are

likely to have some impact on terrestrial ecosystem.

However, there will be no net increase in air pollution. Treated effluent

will be incinerated and the solid wastes will be collected and disposed

off properly. Hence, negligible impact on ecology is expected.

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SPPL has developed a greenbelt / green cover in about one third of its

total area and sufficient number of plants has been planted in the

premises.

4.3.2.7 Socio – Economic Pattern

The project to manufacture bulk-drugs is likely to have certain positive

impacts on socio-economic environment.

Positive Impacts :

Direct employment generation potential of the project will be for

about 30 persons.

Various modes of indirect employment i.e. transportation, increased

business opportunities to shopkeepers etc. will also be there.

(Local people will be given preference, on merits, wherever found

suitable for all the jobs in the plant, direct as well as indirect).

Over-all improvement in quality of life of people of the study area.

SPPL is committed to the socio – economic up-lift of the area and has

donated computer to the school of the nearby village of Varsola and

has also contributed towards face lift and upkeep of crematorium of Vil.

: Varsola.

Thus, it can be said that the proposed project will have significant

beneficial impact on the socio-economic scenario of the study area.

4.3.2.8 Health and Safety

Various project activities like storage and transportation of raw

materials and finished goods, gaseous emissions, movement of

equipments etc. are likely to have some impact on health and safety of

personnel.

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All the staff and workers will be covered under health insurance

scheme (i.e. ESI), which is statutorily required by Government of India.

Health check up of all employees will be carried out by medical

practitioners, every year, at company’s cost. Whenever required,

special assistance will be provided for medical treatment.

Emergency / Minor Medical Treatment

Company shall retain a medical practitioner in nearby area for providing

quick relief in the event of any accident. The medical practitioner will

also offer medical treatment in the event of minor medical problems

originating during working hours.

Safety

Employees working on the shop floor will be provided with normal

protective wears such as shoes, helmets, hand gloves and respirator

masks wherever required. A list of Personal Protective Equipment has

been enclosed as ANNEXURE - 13. Various safety teams for different

areas of operation will be formulated. A safety officer will co-ordinate

the activities of these teams. The teams have responsibility to promote

safety measures in respective areas. At production locations where

fire hazards exist, systematic fire control equipments will be installed.

Hence, as described briefly above, the proponents of the project have

incorporated all the necessary safety aspects in planning, designing

and operation of the plant as per international practices. These safety

aspects would be adequate for the project. Hence, the impact on this

account has been adequately safeguarded.

Various impacts of operation phase alongwith their characteristics are

summarized in TABLE NO. – 4.2.

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TABLE NO. 4.2

IMPACT MATRIX FOR OPERATION PHASE

Activity Raw Production / Product Transportation Gaseous Effluent Solid Employment Green Belt Rain Water Materials Manufacturing Storage of Product Emissions Treatment Waste Development Harvesting & Storage & and and Raw Generation Recharge Parameter Handling Handling Material Air No Impact -ve, LT No Impact -ve, ST -ve, LT -ve, LT No Impact No Impact +ve, LT No Impact Water No Impact -ve, LT No Impact No Impact No Impact -ve, ST No Impact No Impact +ve, LT + ve, LT Noise Negligible -ve, LT Negligible -ve, ST No Impact -ve, LT No Impact -ve, LT +ve, LT No Impact Odor No Impact No Impact No Impact No Impact No Impact No Impact No Impact No Impact +ve, LT No Impact Flora No Impact No Impact No Impact No Impact No Impact No Impact No Impact No Impact +ve, LT + ve. LT Fauna No Impact No Impact No Impact No Impact No Impact No Impact No Impact No Impact +ve, LT + ve, LT Soil No Impact No Impact No Impact No Impact No Impact No Impact No Impact No Impact +ve, LT + ve, LT Forest No Impact No Impact No Impact No Impact No Impact No Impact No Impact No Impact No Impact No Impact Religious / Historical Places

No Impact No Impact No Impact No Impact No Impact No Impact No Impact No Impact No Impact No Impact

Population No Impact +ve, LT No Impact +ve, LT No Impact No Impact No Impact No Impact +ve, LT + ve, LT Cultural No Impact No Impact No Impact No Impact No Impact No Impact No Impact +ve, LT No Impact No Impact Health and Safety Negligible Negligible Negligible Negligible Negligible Negligible No Impact No Impact +ve, LT No Impact

+ ve – Positive (beneficial) ST – Short Term - ve – Negative (adverse) LT – Long Term Negligible - Negligible Impact

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CHAPTER – 5

ENVIRONMENTAL MANAGEMENT PLAN

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Chapter – V

Environmental Management Plan 5.1 Introduction

Industrial development is associated with few positive impacts and few

negative impacts on the environment. The negative impacts should not hinder

industrial development but they should be properly mitigated.

An Environmental Management Plan (EMP) has been prepared for the

bulk-drug manufacturing of SPPL to minimize negative impacts and is

formed on the basis of prevailing environmental conditions and likely

impacts of this project on various environmental parameters. This plan

will also facilitate monitoring of environmental parameters.

EMP includes scheme for proper and scientific treatment and disposal

mechanism for air, liquid and solid hazardous pollutants. Apart from this,

green belt development, safety aspect of the workers, noise control, fire

protection etc. are also included in it.

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5.2 Purpose Of Environmental Management Plan

Various purposes of the environmental management plan are:

To treat and dispose off all the pollutants viz. liquid, gaseous and

solid waste so as to meet statutory requirements (relevant

pollution control Acts) with appropriate technology.

To support and implement development work to achieve

environmental standards and to improve the methods of

environmental management.

To promote green-belt development.

To encourage good working conditions for employees.

To reduce fire and accident hazards.

Budgeting and allocation of funds for environment management

system.

To adopt cleaner production technology and waste minimisation

program.

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5.3 Details of Environmental Management Plan 5.3.1 Construction and Commissioning Phase 5.3.1.1 AIR ENVIRONMENT As SPPL has complete infrastructure suitable for bulk-drug

manufacturing, no major construction activity will be required to be

carried-out. Only minor civil work like foundation of new vessels etc.

will be carried-out. During construction activities, minor emission of dust and

gases from movement of vehicles and construction activity is expected.

However, following measures will be taken to reduce / contain such emissions

:

Water will be sprinkled on loose top soil to prevent re-suspension of

dust into ambient air due to movement of vehicles etc.

Separate civil construction material storage yard will be created

within the site and it will be enclosed.

Cement bags will be separately stored under cover in bales. Sand

will be stacked under tarpaulin cover.

Transport vehicles and construction equipments / machineries will be

properly maintained to reduce air emissions.

Idle running of vehicles will be minimized during material loading /

unloading operations.

All construction workers will be provided appropriate PPEs like dust mask,

ear plug, helmet, safety belt etc. and made to wear them during working

hours.

5.3.1.2 WATER ENVIRONMENT

Maximum water requirement for construction purpose including domestic

water requirement of construction workers is estimated to be approximately 2

cu. mt. per day. It will be supplied from the existing bore well. Water quantity

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being small, no major impact on existing water resources of the study area is

envisaged.

Further, there will be no housing facility at site for construction workers and

hence a major source of impact on water environment will be avoided.

Proper and sufficient sanitary facility already exists at site in the form of

Septic tank / Soak pit system of adequate capacity.

5.3.1.3 SOLID WASTE

Main solid waste generation during construction phase will be construction

debris like rubble, brick bats, debris, steel scrap, wooden scrap, sand, gravel

etc. However, these materials are inert in nature and will not result into

leaching of any substance or constituent.

These materials will be properly sorted and will be used within premises for

filling of low lying areas. Wooden scrap, steel scrap will be given to scrap

dealers.

On completion of civil work, all debris etc. will be completely removed from

site to avoid any incompatibility with future use.

5.3.1.4 NOISE ENVIRONMENT

Following measures are proposed during construction period to mitigate

adverse impacts :

All machineries to be used for construction purpose will be of highest

standard of reputed make and compliance of noise pollution control norms

by these equipments will be emphasized by SPPL.

All construction workers working in high noise areas will be provided

appropriate PPEs like ear muffs and made to wear them during working

hours.

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5.3.1.5 LAND ENVIRONMENT

Following steps are proposed to take care of impact of construction activity on

project land area :

On completion of civil work, all debris etc. will be completely removed from

site to avoid any incompatibility with future use.

Other material like paints, diesel etc. will be properly stored and handled

to prevent any spillage on land.

All the wastes will be stored at a designated site within the premises to

prevent scattered discharge on land.

5.3.1.6 ECOLOGY

Project site is an existing unit with number of shrubs and trees. No tree

cutting exercise will be there and no major impact on ecology is

anticipated.

5.3.1.7 SOCIO - ECONOMIC

As there will be no temporary housing colony for construction workers,

no socio – economic impact due to the same is envisaged.

Over – all socio – economic effect of construction phase will be positive

due to direct and indirect employment opportunity for the local

population.

5.3.2 Operation Phase Operation phase of any industry being longer in duration and because

of its’ potential to create continuous impacts, is much more important

from the environmental impact point of view and a comprehensive and

effective EMP has to be prepared and implemented to safe-guard

environmental concerns during operation phase of any unit.

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5.3.2.1 AIR ENVIRONMENT

Following measures are proposed to mitigate negative impact of

operation phase of the project on the surrounding air environment :

Existing scrubbers will be used to take care of process emissions

from the proposed project.

Height of scrubber vent is as per statutory requirement. The vent

has stack monitoring facility (SMF) consisting of sampling port-hole,

platform and access ladder.

Adequate spares of critical components of scrubber system are kept

to ensure trouble – free operations and continuous compliance to

emission norms.

A comprehensive plan for fugitive emission control is prepared as

outlined in CHAPTER - 2.

Transport vehicles will be properly maintained to reduce air emissions.

Vehicles will be periodically checked for pollutant emissions against

stipulated norms.

Idle running of vehicles will be minimized during material loading /

unloading operations.

5.3.2.2 WATER ENVIRONMENT Total water requirement for operation phase of the proposed project is

estimated at 21.5 cu. mt. per day and is proposed to be met through

own bore-well.

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To compensate and mitigate impact on ground water availability in the

area due to continuous withdrawal of ground water by the project to the

tune of 21.5 cu. mt. Everyday (effective increase of 4.0 cu. mt. per

day), a rain water recharge scheme has been developed and its details

are given in ANNEXURE - 12.

Treated industrial effluent (3.5 cu. mt. per day) will be incinerated in the

in-house incinerator. Similarly, domestic sewage (1.7 cu. mt. per day)

will be disposed off through septic tank / soak pit system.

5.3.2.3 SOLID WASTE

Hazardous wastes i.e. used oil and solvent residue will be stored in

200 liter MS barrels while ETP sludge and spent Carbon / Hyflow

etc. will be stored in polythene bags.

Above stated hazardous wastes along with discarded drums / containers will be stored separately in the existing “Solid Waste Storage Area” within the factory premises. It has non – percolating R.C.C. floor, covered roof and leachate collection system. The storage area has proper illumination and ventilation and equipped with fire extinguisher device wherever required. A sign – board is put out-side the storage area marked “Hazardous Waste Storage Area” and “Danger”. Area of this storage site is approx. 30 m2 and volume approx. 100 m3.

Hazardous wastes will be disposed in following manner :

used oil will be given to CPCB registered recycler / re-processor of oil.

Solvent residue will be incinerated in in-house incinerator or will be given to common incineration facility of BEIL at Bharuch, Gujarat.

ETP sludge and spent Carbon / Hyflow will be disposed off into

TSDF of NEPL at Ahmedabad.

Discarded containers after decontamination will be given to registered vendor.

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5.3.2.4 NOISE ENVIRONMENT

Following precautionary measures will be adopted to control the noise level :

o Roof of buildings is constructed of reinforced concrete.

o Walls and ceilings of buildings will be lined with sound absorbing materials,

wherever required.

o Noise generating sources will be maintained properly to minimize noise

generated by them.

o Personnel working near the noisy machines in different plant locations will be

provided with well designed ear muffs / plugs (effective noise reduction 10-15

dBA).

o Green belt will act as a noise barrier.

o Training will be imparted to personnel to generate awareness about effects of

noise and importance of using PPEs.

5.3.2.5 LAND ENVIRONMENT

There will be no net increase in air pollution due to manufacture of

proposed bulk – drugs as outlined in Chapter – 4 of this report.

All the hazardous wastes to be generated from the project will be

properly stored and disposed off.

Treated industrial effluent will be incinerated in in-house incinerator.

Domestic sewage will be disposed off through septic tank / soak pit

system.

Thus, no impact on land is envisaged due to discharge of gaseous

emission, solid waste or liquid effluent from the proposed unit.

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5.3.2.6 BIOLOGICAL ENVIRONMENT

5.3.2.6.1 GREEN BELT DEVELOPMENT

Development of green belt contributes to aesthetic improvement of an area

and also helps in controlling air pollution. Trees of a green belt, due to

large surface area of their leaves, collectively provide a natural basin

for various air pollutants. A well developed green-belt helps in

intercepting particulate matter and gaseous pollutants and obstructs

their passage to the ground. Trees also provide cushion in the event of

any sudden discharge of pollutants.

The plantation at the project site consists of Chiku (Manilkara zapota L), Limbdo

(Azadirachta indica A.Juss), Gulmahor (Delonix regia(Boj)) and Badam (Terminalia

catappa L.). Further plantation, if required, will be carried-out after interaction

with local experts and various species will be selected as per CPCB

guidelines.

An important aspect of a greenbelt is that the plants are living organism with

their varied tolerance limit towards the air pollutants. A green belt is effective

as a pollutant sink only within the tolerance limit of constituent plants.

Planting few, known pollutant sensitive species along with the tolerant species

within a green belt is desirable.

5.3.2.6.2 SELECTION OF TREES For development of greenbelt it is advisable to avoid mono culture of tree

specie due to climatic and other reasons. Instead, planting of varieties of tree

species should be planned to take advantage of diversity and uniform up take

of nutrients etc.

In general, following factors have been considered for the selection of

tree species for plantation at the plant site :

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The trees must be tolerant to all the pollutants present in the

area.

The trees should be able to grow and thrive on soil.

The trees should maintain ecological, land and hydrological

balance of the region.

The trees should be fast growing and indigenous.

Characteristics of plants mainly considered for affecting absorption of

pollutant gases and removal of dust particle are as follows.

For absorption of Gases :

1) Tolerance towards pollutants in question, at concentrations that are not too

high to be instantaneously lethal

2) Longer duration of foliage

3) Freely exposed foliage

4) Adequate height of crown

5) Openness of foliage in canopy

6) Big leaves( long and broad laminar surface)

7) Large number of stomatal apertures

Plantation along road sides

Automobiles are the source of pollution of gaseous and particulate pollutants.

Component of green belt on road side hence should be with both absorbers

of gases as well as of dust particles. The choice of plants for road side should

include shrubs of height 1 to 1.5 meter and trees of 3-5 meter height. Medium

sized trees, alternating with shrubs are ideal for sorption of particulates and

gases.

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TABLE NO. 5.1

RECOMMENDED PLANT SPECIES FOR GREEN BELT DEVELOPMENT Plant species Habit Tolerance

limit To Dust

Stomatal index

Mode of Regeneration

Acacia auriculiformis Tree Tolerant 10.9 Seeds Acacia catechu Tree 8.24 seeds Acacia leucocephala ( Hari baval)

Shrub T 12.01 seeds

Ailanthus excelsa Tree T 13.01 Seeds, shoot, root cuttings

Albizia lebbeck Tree T 19.72 Seeds Albizia procera Tree T 20.21 seeds Alstonia scholaris ( Devil- tree) Tree T 15.23 Seeds Annona squamosa (Seetaphal) Small tree T 26.19 Seeds, Grafting Anogeissus latifolia (Dhavdo) Tree T 18.72 Seeds Azadirachta indica Tree T 29.2 Seeds Bauhinia purpurea Tree T 23.58 Seeds Bauhinia racemosa (Aasundro) Small tree T 25.68 seeds Bougainvillea spectabilis Shrub T 32.53 Cutting Caesalpinia pulcherrima (White gold mohur)

Tree T 29.09 Seeds and Cuttings

Calotropis gigantea Shrub T 9.93 Seeds Calotropis procera Shrub T 10.32 Seeds Cassia fistula Tree T 20.4 Seeds and

suckers Cassia siamea Tree T 21.2 Seeds Cordia dichotoma (Gunda) Tree T N.A Seeds/ stem

cuttings Delonix regia ( Gulmohur) Tree Sensitive 14.38 Seeds /stem

cutting Emblica officinalis( Amli) Tree T 11.62 Seeds /stem

cutting Euphorbia tirucalli Shrib T NA Cuttings Ficus bengalensis (Vad) Tree T 21.72 Seeds /stem

cutting Ficus hispida Tree T 17.21 Seeds /stem

cutting Ficus religiosa (papal) Tree T 18.70 Seeds /stem

cutting Hibiscus rosa-sinensis Small tree T 23.32 stem cutting Ixora arborea Small tree T 17.3 stem cutting Ixora rosea Small tree T 20.30 Stem cutting Jatropha curcas Shrub T NA Lantana camara Shrub T 12.13 Seeds /stem

cutting Lawsonia inermis (Mendi) Shrub T 17.0 Seeds /stem

cutting

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Mangifera indica ( Am) Tree T 30.77 Seeds/ grafting/ budding/

Manilkara zapota (Chikoo) Tree T 25.78 Grafting Melia azadirachta Tree T Seeds /stem

cutting Nerium indicum Shrub T 15.7 Cutting Peltophorum pterocarpum Tree T 16.68 Seeds Polylathia longifolia Tree T 22.27 Seeds Sesbania sesban ( Shrub T 19.2 Seeds Tamarindus indica Tree T 18.4 Seeds Tectona grandis Tree T 23.48 Seeds Terminalia alata Tree T NA Seeds /stem

cutting Thespesia populnea Tree T 29.81 Seeds /stem

cutting Thevetia peruviana Shrub T 27.8 Seeds /stem

cutting Zizyphus mauritiana (Bordi) Tree T 12.4 Seeds /stem

cutting

T: Tolerant, NA =Not available Highlighted species are most suitable for this locality, considering its terrain and other existing vegetative cover in the study area Sources: CPCB (March ,2000) PROBES/75/1999-2000 PLANTATION AREA About 4,000 m2 of land is allocated for greenbelt / green cover development

at the project site of SPPL. Proper budgetary provision considering expenses

incurred on saplings, soil handling, manuring, after care and maintenance is

made.

5.3.2.7 SOCIO – ECONOMIC ENVIRONMENT

SPPL is committed to the socio – economic up-lift of the area and has

donated computer to the school of the nearby village of Varsola and has also

contributed towards face lift and upkeep of crematorium of Vil. : Varsola.

Moreover, various modes of indirect employment i.e. transportation,

increased business opportunities to shopkeepers etc. will also be there.

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5.3.2.8 HEALTH AND SAFETY

Following measures will be adopted in the plant :

Regular inspection and maintenance of pollution control systems.

All measures related to safety such as safety appliances, training,

safety awards, posters, slogans are undertaken.

The workers exposed to noisy sources are provided with ear

muffs/plugs.

Adequate facilities for drinking water and toilets are provided to the

employees.

The fire and safety equipments are properly utilized and maintained

regularly.

The health of the workers will be regularly checked by a well qualified

doctor and proper records will be kept for each worker.

Isolated storage for all hazardous chemicals with adequate safety

measures, sign board outside storage etc.

Fire – proof electric fittings will be used.

Good air circulation will be ensured within the plant area.

Workers will be provided training to deal with emergency situation, to

operate fire extinguishers, to provide first – aid to affected persons by

arranging safety work-shop once in six months.

Showers and hand – wash will be provided in vicinity of work area with

ample quantity of water available.

Fire and Smoke detectors will be installed at suitable place in the

premises to get alert warning and avoid major accident.

On site emergency plan will be prepared and implemented to safe guard

human life and property.

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Moreover, SPPL based on past occupational health record of its’ existing unit, does not anticipate any adverse effect on health of workers.

5.3.2.9 GENERAL CONSIDERATIONS

For good house keeping of the project, following measures will be

planned :

Maintaining cleanliness of roads to prevent accumulation of dust

and waste material.

Inculcating positive attitude among employees for good house –

keeping.

Maintaining hygienic conditions near drinking water source and

toilets.

5.3.2.10 Waste - minimization, Recycle / Reuse / Recover Techniques, Energy Conservation & Natural Resource Conservation :

Unit will take following steps in this regard :

1. Recovery of solvents will be more than 95 % and these recovered

solvents will be recycled back to the process.

2. High efficiency pumps with auto level cut off will be installed.

3. Liquid chemicals dosing will be through metering pumps.

4. CFLs with high frequency ballast shall be used.

5. Energy efficient fluorescent tube lights (T-5)/ CFL shall be used for

office areas.

6. Self starters and variable drives will be installed for motors.

7. All tanks will be installed with level controllers and cut off for pumps.

8. Process improvement by R & D to reduce waste water generation.

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5.4 Environmental Management Cell

In addition to preparing an EMP, it is also necessary to have a permanent

organizational set up to ensure its effective implementation. Hence, SPPL will

create a team consisting of officers from various departments to co-ordinate

the activities concerned with management and implementation of the

environmental control measures. This team will undertake the activity of

monitoring the stack emissions, ambient air quality, noise level etc. either

departmentally or by appointing external agencies wherever necessary.

Regular monitoring of environmental parameters will be carried - out to find

out any deterioration in environmental quality and also to take corrective

steps, if required, through respective internal departments.

The Environmental Management Cell will also collect data about health of

workers, green belt development etc. Organogram of the Environmental

Management Cell is presented in FIGURE NO. – 5.1.

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FIGURE NO. 5.1

ORGANISATIONAL SET UP FOR ENVIORMENTAL MANAGEMENT PLAN

Environment Management Cell

The cell will also be responsible for monitoring of the plant safety and safety

related systems which include :

Checking of safety related operating conditions.

Visual inspection of safety equipments.

Preparation of a maintenance plan and documentation of maintenance

work specifying different maintenance intervals and the type of work to

be performed.

Other responsibilities of the cell will include :

Conduct and submit annual Environmental Audit (in Form – V). A

Director

Dy. Manager (Env.)

Asst. Manager (Safety)

Officer (Safety)

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GPCB registered agency will be retained to generate the data in

respect of air, water, noise, soil and meteorological data and prepare

the Environmental Audit report. This report will be submitted to the

GPCB every year before 30th September. Timely renewal of

Consolidated Consents & Authorization (CC & A) will also be taken

care of.

Submitting environmental monitoring report to GPCB. Data monitored

by the cell will be submitted to the Board regularly and as per the

requirement of GPCB. The cell will also take mitigative or corrective

measures as required or suggested by the Board.

Keeping the management updated on regular basis about the

conclusions / results of monitoring activities and propose measures to

improve environment preservation and protection.

Conducting regular safety drills and training programs to educate

employees on safety practices. A qualified and experienced safety

officer will be responsible for the identification of the hazardous

conditions and unsafe acts of workers and advise on corrective

actions, organise training programs and provide professional expert

advice on various issues related to occupational safety and health.

Conducting safety and health audits to ensure that recommended

safety and health measures are followed.

5.5 Monitoring Of Environment

A regular monitoring of environmental parameters like air, water, industrial

effluent, noise and soil as well as performance of pollution control facilities

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and safety measures in the plant are important for proper environmental

management of any project. Therefore, the environment and safety cell will

handle monitoring of air and water pollutants as well as the solid wastes

generation as per the requirements of Gujarat Pollution Control Board and

Central Pollution Control Board.

ADVANTAGES OF MONITORING : Monitoring of various parameters will be carried out regularly to :

find out pollution level inside the plant and in nearby area compile pollution related data for remedial measures find out efficiency level of pollution control measures adopted

TABLE 5.2 MONITORING SCHEDULE FOR ENVIRONMENTAL PARAMETERS

Sr. No.

Partiulars Monitoring Duration Important Parameters

1 AIR POLLUTION A Scrubber Monitoring Once in a

month Grab HCl

B Incinerator stack Once in a month

Grab PM, SO2 & NO2

C Ambient Air Quality (i) At 1 location inside the Plant

Premises Once in a month

24 hrs Continuously

PM2.5, PM10, SO2, NO2 & HCl

(ii) At 1 location in Prevalent Down Wind Direction

Once in a month

24 hrs Continuously


(iv) At 1 location in Up Wind Direction

Once in a month

24 hrs Continuously


2 WATER QUALITY A Water Quality in the Study Area (i) Ground Water inside the plant

premises Once in a month

Grab pH, Colour, Turbidity, TSS, TDS, COD, Chlorides, Sulphates, Total Alk., Ca & Mg

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Hardness, Fluoride etc. (ii) Ground Water out side the plant

at 1 location Once in a month

Grab -- do --

3 INDUSTRIAL NOISE LEVELS

At various locations within premises

Once in a month

24 hrs Continuous with

one hour interval

Noise Levels in dB(A)

Laboratory Facilities No separate laboratory facility for analysis of above stated parameters will be

created by SPPL looking to the size of the project. Instead, services of a

GPCB registered laboratory will be taken for this purpose.

5.6 BUDGETORY PROVISIONS FOR EMP Adequate budgetary provisions have been made by SPPL management for

execution of environmental management plan. The details of capital and

recurring (per annum) budget earmarked for pollution control, operation and

maintenance of pollution control facilities, for greenbelt development and

maintenance will be as given in TABLE NO. 5.3 below :

TABLE NO. 5.3 Cost of environmental protection measures (Rs. in Lakhs)

Sr. No.

Capital Cost Recurring cost per Annum

1. Air Pollution Control 1.00 2.50 2. Water Pollution Control 3.00 25.00 3. Noise Pollution Control 0.50 0.25 4. Environment Monitoring and

Management 0.00 1.50

5. Occupational Health 1.00 0.50 6. Green Belt 5.00 1.50

TOTAL 10.50 31.25

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CHAPTER – 6

RISK ASSESMENT & DISASTER MANAGEMENT PLAN

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6.1 RISK ASSESSMENT The bulk – drug project of SPPL will store, handle and consume a no. of

flammable chemicals. Hence, a consequence analysis has been carried – out

related to accidental fire and explosion exposure of the proposed ‘Storage

Shed’ which would be used for storage of flammable chemicals.

As per Loss Prevention in Process Industries by Frank E. Lees, drum failures

accounts for around 76 accidents out of 2108 accidents in Chemical

Industries.

The accidental occurrence of fire or explosion in the proposed storage shed

could cause strain on the operational activity of the project. Hence, the main

purpose of consequential effect analysis is to provide useful tool for mitigation

of adverse effect of occurrence of accidental fire or explosion involving

‘Storage Shed’

For the purpose of consequence analysis, internationally renowned fire &

explosion evaluation software developed by “Swiss Re” known as “ExTool”

has been used.

6.1.1 CONSEQUENCE ANALYSIS

The project will store, handle and consume a no. of flammable chemicals. List

of such chemicals is given in TABLE NO. 6.1. Properties related to fire and

explosion hazards of these chemicals are given in TABLE NO. 6.2. The

chemicals would be stored mostly in 200 ltrs. drums. However, some of the

chemicals will also be stored in smaller drums of capacity 10 ltrs., 20 ltrs. etc.

All such drums will be stored in a designated place to be known as ‘Storage

Shed’ of area 66 sq. mt. (12 m. x 5.5 m.). The Storage Shed is shown on the

lay – out of the project given at FIGURE NO. 6.1.

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The ‘Storage Shed’ will be located atleast 30 mtrs. away from the

manufacturing process block.

Following constructional features are presumed for the shed :

• ‘Storage Shed’ will be a pucca room of RCC construction.

• Flooring will be provided with 10 cm high kerbing all around and will be

connected to proper draining facility.

• The slope of the flooring of the Storage Shed would be towards the entry door

and the door would not be provided any door sill foe easy movement of

materials.

• The front yard of the Storage shed would be paved along the length of the

Spare Room (12 meters) and breath of the front yard assumed to be around 3

meters. The total paved area in front of the Spare room would be (12mX3m)

36 sq. mt.

FIGURE NO. 6.1

30 mtr.

Storage shed

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TABLE NO. 6.1

List of Flammable Chemicals

Name of Hazardous Chemical Storage No for Drums / Bag

Unit Qty. No of

Container

Type

Acetic Acid Kg 500 15 Carboys

Acetone Ltr 1800 9 Drums

Acrylonitrile Kg 320 2 Drums

Methanol Ltr 1000 4 Drums

Iso Propyl Alcohol Ltr 600 8 Drums

Benzyl Chloride Kg 300 10 Carboys

Pyridine Kg 200 1 Drum

Tetra Hydrofurane Ltr. 200 1 Drum

Toluene Ltr. 200 1 Drum

N- Hexane Ltr. 400 2 Drums

Ethyl Acetate Ltr. 800 4 Drums

Acetonitrile Ltr. 200 1 Drum

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TABLE NO. 6.2

Fire and Explosion Related Properties of Flammable Chemicals

Sr.

No.

Hazardous Chemical Flash Point 0C

Lower

Flammability

Limit %

Upper

Flammability

Limit %

1 Acetic Acid 39 6.0 17.0

2 Acetone - 18 2.2 13.0

3 Acrylonitrile 0 3.0 17.0

4 Methanol 12 5.5 44

5 Iso Propyl Alcohol 12 2.0 12

6 Benzyl Chloride 67 1.1 14.0

7 Pyridine 20 1.8 12.4

8 Tetra Hydrofurane - 14 1.5 12.0

9 Toluene 4.4 1.1 7.1

10 N- Hexane - 32 1.0 7.0

11 Ethyl Acetate - 4 2.2 11.5

12 Acetonitrile 12.8 3.0 16.0

6.1.2 LOSS SCENARIOS

The consequence analysis of the fire & explosion scenario is based on the

visualization of Most Credible Loss Scenario (MCLS) development and

subsequent modeling of the same scenario to carry out further analysis.

The MCLS visualized for the ‘Storage Shed’ are as under : It is envisaged that a few 200 lit highly flammable liquid drum (may be toluene or IPA) would leak heavily may be due to bottom corrosion and would flow through the gap between floor and the door due to absence of any door sill and form a pool of flammable liquid in entire front paved yard (36 sq. mt.) of the Storage Shed. Following two sub scenarios are highly expected under this circumstance:

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a. Scenario 1. There could be huge fire due to ignition of entire pool of

flammable liquid engulfing 36 sq. mt. of area.

b. Scenario 2. Formation of a flammable vapour cloud due to rapid

evaporation of flammable liquid and subsequent Vapour Cloud Explosion

(VCE).

To be conservative, it is assumed that content of at least one 200 litre drum of Acetone / Methanol /Hexane would form vapour cloud and cause Vapour Clod Explosion (VCE)

The scenarios envisaged are based on recorded past experiences with an

objective to simulate the effect of probable maximum damage that could be

caused by such accidents.

The internationally renowned fire & explosion evaluation software developed

by “Swiss Re” known as “ExTool” has been used for analyzing consequences

of visualized MCLS.

6.1.2.1 Interpretation of Data

Fire

The heat radiation effects scenarios like Pool fire have been evaluated based on following standard effects built-in in the computer programme. (ExTool) For radiation intensities > 3.6 W/sq. cm. fire will propagate For intensities between 1.2 and 3.0 W/sq. cm. no propagation if enough cooling water is applied For radiation intensities < 0.8 W/sq. cm. no propagation For fire-fighters : 0.8 W/sq. cm. Absolute approach limit 0.5 W/sq. cm. Limit with normal protective clothing Blistering on skin in 30 sec. Pain on skin in 10 sec. 0.15 W/sq. cm. Limit without protective clothing Reference API

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Explosion

The evaluation of the effect of VCE has been carried out based on reference

standard effects built-in in the computer programme which is as under.

Mbar (Level of Over-

pressure)

Effect of Explosion

1.4 Annoying noise

3 Loud noise

7 – 10 Window pane 5% broken

14 – 30 Window pane 50% broken; some damage to ceilings & tiling

30 – 60 Window pane 90% broken; minor structural damage

30 – 50 Tiles displaced

60 – 90 Doors and window frames broken

70 – 140 Corrugated steel or aluminum panel’s fastenings fail; steel

frame of clad building slightly distorted.

140 – 200 Non-reinforced concrete walls shattered; steel frame buildings

suffer heavy damage or distortion

140 – 280 Partial or total collapse of roof, partial demolition of one or two

external walls, severe damage to load-bearing partitions.

350 – 800 50 – 75% of external brickwork destroyed

800 – 2600 Almost complete demolition of houses

700 – 1700 Telegraph poles destroyed

1700 – 3800 Large trees destroyed. Ref. Lees - Loss prevention in Process Industries, & Sixth Int. Mtg of Forensic Sciences Edinburgh (19720)

However for the purpose of realistic interpretations and to asses the quantum

of damage, following scale is used (Development of Over Pressure Vs

probable damage percentage).

Over Pressure (mbar) Expected Damage % 0.02 5% 0.13 40% 0.20 80%

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6.1.3 Results :

Fire (Scenario 1)

Scenario : Fire in the front yard of Storage Shed.

Formation of huge pool of highly volatile & flammable liquid in front yard of the Storage Shed due to considerable leakage of drum stored and subsequent ignition of accumulated pool of flammable liquid. The probable effects of the fire scenario are enumerated below in TABLE NO. 6.3 graphical presentation of computer output is given in FIGURE NO. 6.2. While modeling the scenario, following points are assumed

• The equivalent area of the pool of fire is considered as circular area of radius

3.38 mt. (area - 36 sq. mt.)

• Property of light hydrocarbon has been considered as fire property

TABLE NO. 6.3

Effect of the Heat Flux for Fire Propagation

Radiation Energy level W/cm2

Distance in meter

3.60 10 3.0 11 1.2 190.8 24 0.5 31 1.5 58

Explosion (Scenario 2)

Scenario : Vapour Cloud Explosion

It is envisaged that due to formation of vast pool of highly volatile flammable

liquid in front yard of Storage Shed, vapour cloud would form and result into

Vapour Cloud Explosion (VCE). While modeling VCE, it is assumed on very

conservative basis that the content of at least one drum that is around 200

lits. (equivalent to around 5% of the amount of flammable liquid proposed to

be stored in Storage shed) of flammable chemical would be the mass of the

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vapour cloud. The properties of n-Hexane have been taken as standard for

modeling. Results of VCE scenario envisaged are enumerated in TABLE NO.

6.4 below and graphical presentation of computer output is given in FIGURE

NO. 6.3 :

TABLE NO. 6.4

Result of VCE

Over Pressure bar Damage Distance,

in meter

Expected Damage %

0.02 53 5%

0.13 34 40%

0.20 19 80%

6.1.3.1 INTERPRETATION OF THE RESULTS

It can be inferred from the VCE results that even if content of only one highly

flammable liquid forms a vapour cloud and subsequently ignited to result into

VCE in front of the Storage Shwed, considerable damage (around 40%) is

expected to be caused to the production blocks located 30 meters away from

the Storage Shed (critical distance is 34 meters) used for hazardous

chemicals storage. However, no appreciable damage is expected to the

production blocks if fire breaks out in front of the Spare Room due to

formation of pool of highly flammable liquid. (critical distance from fire point of

view is only 11 m).

As practically no buffer distance is available in case of occurrence of VCE, it

is better to incorporate all the safety norms as standard operating procedure

while handling the hazardous chemicals in the Storage Shed. Therefore,

considering all the practical aspects, the distances proposed in the layout

plan from the process blocks to Storage Shed appear to be very safe from fire

point of view but not from VCE angle.

Fire may also travel through drains located in the vicinity of Storage Shed.

Therefore, incorporation of flame trap in the drain close to Storage Shed is

suggested.

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FIGURE NO. 6.2

Graphical representation of effects of fire

FIGURE NO. 6.3 Graphical representation of VCE

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6.2 DISASTER MANAGEMENT PLAN

6.2.1 INTRODUCTION

Disaster

An emergency is said to have arisen when operators in the plant are not able to

cope up with a potential hazardous situation i.e. loss of control of an incident

causes the plant to go beyond its normal operating conditions, thus creating

danger. When such an emergency evolves, chain of events affect the normal

working within the factory area and / or which may cause injuries, loss of life,

substantial damage to property and environment both inside and outside the

factory and a DISASTER is said to have occurred.

The various steps involved in the process of DISASTER MANAGEMENT can

be summarized as :

(1) Minimize Risk Occurrence (Prevention)

(2) Rapid Control (Emergency Response)

(3) Effectively Rehabilitate Damaged Areas (Restoration)

Disaster Management Plan is evolved by careful scrutiny and interlinking of :

(a) Types and causes of disaster.

(b) Technical know – how.

(c) Resource availability.

Types of Disaster

The various types of Disaster that may occur are :

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(i) Due to fire and

(ii) Hurricane, cyclone and other natural calamities.

6.2.2 OBJECTIVES OF PLAN

This plan is developed to make best possible use of resources at the command

of SPPL to :

Rescue the victims and treat them suitably.

Safeguard others (evacuating them to safer places).

Contain the incident and control it with minimum damage.

Identify the persons affected.

Preserve relevant records and equipment needed as evidence incase on

an inquiry.

Rehabilitate the affected areas.

6.2.3 IDENTIFICATION OF MAJOR HAZARDS

• Fire Hazard.

6.2.4 SCOPE OF PLAN

The plan will set into action immediately after a fire occurs inside the plant.

However, as stated in risk assessment, fire hazard will be restricted to area

surrounding storage shed.

6.2.5 BASIS OF PLAN

SPPL will prepare an onsite emergency plan. The basic guidelines of the plan

are as given below :

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1) Informative brochure on emergency will be distributed to each staff

member of the plant and telephone numbers of key personnel to be

contacted during an emergency will be placed at all the operator

placement point in the plant.

2) SPPL will have a direct tele-link service line with the nearest Fire Station in

case of severe emergency.

3) Workers would be trained regularly on fire hazard drill, which will be

organized once in a month by the safety and fire department.

4) Various locations would be covered with fire hydrant systems that would

be tested and put into operation in such a manner that it remains

operational during emergency.

5) 24 hours vehicle for service and in – plant first aid emergency kit would be

provided.

6) Coded colours for pipeline will be used as per IS.

6.2.6 POST DISASTER ANALYSIS AND EVALUATION

When an emergency is over, it is desirable to carry out a detailed analysis of

the causes of the accident to evaluate the influence of various factors involved

and to propose methods to eliminate or minimize them in future.

Simultaneously, the adequacy of the disaster preparedness plan will be

evaluated and any short comings will be rectified.

6.2.7 GENERAL RECOMMENDATIONS

All non – routine work etc. should be carried out under a permit system.

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Adequate number of caution boards high lighting the hazards of chemicals

to be handled, eye baths and emergency showers should be provided at

critical locations.

Adequate number of absorbents should be placed at accessible locations

in the storage shed area that would enable to contain spills immediately.

Adequate colour coding and labeling of the pipelines should be provided

for easy identification of products proposed to be handled through them.

The damage distance due to any failure could be reduced, by reducing the

time required to stop the leak, which in turn would reduce the quantity of

spillage. The response time could be reduced by installing / maintaining

instruments, effective communication system, etc.

It is recommended that rubber mats be provided in front of electrical panel

of the entire plant with a view to prevent employees from receiving electric

shocks.

It is suggested that all type of fire extinguishers be placed at appropriate

places for easy access in case of emergency.

6.2.8 THE AVAILABILITY, ORGANIZATION, AND UTILIZATION OF RESOURCES

FOR EMERGENCIES

In order to maintain emergency response capability, certain facilities must be

kept in a state of readiness, and sufficient supplies and equipment must be

available. Emergency hardware can be classified according to its use during

the response operations. Typical examples are :

Emergency Operation Centres

Communication equipment

Alarm systems

Personal Protection Equipment

Fire fighting facilities, equipment and supplies

Spill and vapour release control equipment and supplies

Medical facilities, equipment and supplies

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Monitoring systems

Transportation systems

Security and access control equipment

It is the responsibility of the Plant Management to ensure that the appropriate

equipments and materials are available to respond to hazard – specific

emergencies at the site.

6.2.9 COMMAND, CO – ORDINATION AND RESPONSE ORGANIZATION

STRUCTURE

One of the most important objectives of emergency planning is to create a

response organization structure capable of being deployed in the shortest

possible time during an emergency.

Command and control of an emergency condition encompasses the key

management functions necessary to ensure safeguard of the health and safety

of employees, as well as the public living in the vicinity. These primary functions

are summarized as follows :

a) Detection of the emergency condition

b) Assessment of the condition

c) Classification of the emergency

d) Mitigation of the emergency conditions

e) Notification to management personnel

f) Notification to local, state and governmental agencies

g) Activation and response of the necessary onsite and off – site support

personnel

h) Continuous assessment and reclassifications, as necessary

i) Initiation of protective actions

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j) Aid to affected personnel

k) Recovery and re – entry

The key personnel are nominated with special responsibility according to the

laid down procedures and to make the best use of available resources. The

key personnel are as under :

- Alarm Raiser

- Incident Controller

- Deputy Incident Controller

- Site Main Controller

- Essential Workers

- Other key personnel.

The responsibilities of the above key personnel are as described below :

6.2.9.1 ALARM RAISER

Any person who notices any abnormal incident of hazardous nature will raise

an alarm to make people aware of the scenario. His responsibilities are :

(1) As soon as he notices any incident of hazardous nature i.e. fire,

liquid spillage etc., he will first inform to his superior and co –

worker.

(2) If the hazard is minor, he will try to prevent by using internal resources like

fire extinguishers in case of fire, cover the spillage by sand in case of

liquid spillage.

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(3) If the incident of hazard is major, raise the siren or press the emergency

siren button provided, or ring the bell loudly in case of failure of power

supply.

6.2.9.2 INCIDENT CONTROLLER (IC)

His responsibilities include :

(1) As soon as the sound of siren or bell is heard, he will arrive at the

site of incident.

(2) Take the charge of the scene of the incident.

(3) To assess the scale of emergency. If the emergency is minor, he will start

to activate on – site plan.

(4) As per the incident, direct the essential workers to prevent it by using

extinguishers in case of fire; by covering the liquid spillage by sand or

suitable material in case of liquid spillage.

(5) To send telephonic message to Site Main Controller and key personnel.

(6) Direct the shut down of the plant or part of the plant and evacuate the

plant personnel to assembly point.

(7) Direct all operations within the affected areas with the following priorities.

(a) Secure the safety of personnel.

(b) Minimum damage to plant, property and environment.

(c) Minimize loss of material.

(8) To search for casualties.

(9) To brief Site Main Controller and keep informed of development of situation.

(10) To preserve evidence that will be necessary for subsequent inquiry into

the cause of the emergency and concluding preventive measures.

The Incident Controller shall wear Blue Helmet for his easy identity by all

concerned at the time of emergency.

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6.2.9.3 DEPUTY INCIDENT CONTROLLER (DIC)

In the absence of Incident Controller, the Deputy Incident Controller will

assume the responsibilities of the Incident Controller as given above.

6.2.9.4 SITE MAIN CONTROLLER (SMC)

He is the head authority of the Organization. The technical director holds the

responsibility of the Site Main Controller. He will have over all responsibility for

directing operation and calling for outside help.

The Site Main Controller shall wear White helmet for his easy identification.

The responsibilities and duties of the Site Main Controller include :

(1) Relieve the Incident Controller of his responsibilities of over all charge of

Main Control.

(2) On consultation with Incident Controller and other key personnel, decide

about the type of emergency.

(3) To ensure that key personnel are called in.

(4) To continuously review and assess possible developments to determine

the most probable cause of events.

(5) To direct the safe closure of the plant and evacuate the plant in

consultation with the Incident Controller and other key person.

6.2.9.5 ESSENTIAL WORKERS (EW)

As soon as the Essential Workers hear the emergency siren or any emergency

brought to the knowledge, they will first report to the Incident Controller.

The team of Essential Workers trained in fire fighting, spill control and first – aid

will be made available in the factory round the clock in all shifts.

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Their responsibilities include :

(1) To fight fire or spill control till a fire brigade takes the charge.

(2) To help the fire brigade and mutual aid teams.

(3) To do emergency engineering work like isolation of equipment, materials,

process, providing temporary by-pass line for safe transfer of materials,

urgent repairs and replacement, electrical work etc.

(4) To provide emergency services like power, water, lighting, instruments,

equipment etc.

(5) To move equipment, special vehicles and transport to or from the scene of

incident.

(6) To provide first aid and medical help.

6.2.9.6 OTHER KEY PERSONNEL

Other key personnel are required to provide advice and to implement the

decisions taken by the Site Main Controller in the light of information received

on the situation from the site emergency.

All key personnel will wear Red Helmet for their identification and easy

recognition. The responsibilities and duties of key personnel include :

(1) SAFETY :

The Safety Officer / Supervisor will carry out the following :

(a) To provide necessary equipment like Fire Fighting Equipment (FFE)

and Personal Protective Equipment (PPE).

(b) To accompany Factory Inspector during investigations of the

emergency.

(c) To train workers / supervisors in safety and safe operating

procedures.

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(d) To assist the Site Main Controller, Incident Controller in preparing a

brief report of the incidents.

(2) ASSEMBLY POINTS :

The Assembly Points for gathering non – essential workers / persons will

be fixed and will be clearly marked as per the wind direction.

(3) FIRE CONTROL ARRANGEMENTS :

Fire fighting trained personnel will be made available in all the shifts. The

responsibilities and duties include :

(a) To fight the fire with available internal Fire Fighting Equipment and to

stop leakage of liquids etc.

(b) To provide Personal Protective Equipment to the team.

(c) To cordon the area and inform Incident Controller or Site Main

Controller about the development of emergency.

(d) To train personnel (Essential Workers) to use Personal Protective

Equipment and Fire Fighting Equipment.

(4) MEDICAL ARRANGEMENT :

The responsibilities and duties include :

(a) To provide first aid to the affected persons, and, if necessary, send

them to hospitals for further treatment.

(b) To keep a list of blood groupings ready and updated.

(5) TRANSPORT AND EVACUATION ARRANGEMENT :

For transportation of people, company’s vehicles will be utilized.

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ANNEXURE – 1

CONSOLIDATED CONSENTS AND AUTHORISATION (CC&A) ISSUED BY GPCB FOR EXISTING PRODUCT

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ANNEXURE – 2 MANUFACTURING PROCESS WITH MASS

BALANCE

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ANNEXURE – 2

MANUFACTURING PROCESS ALONGWITH MASS BALANCE

PRODUCT : FAMOTIDINE Brief Process :-

Stage – I 1,3 Dichloro Acetone reacts with Gunyl Thiourea in presence of Acetone and catalyst. Contents are maintained for 16 hrs. and Stage – I compound is obtained. Stage – II & III

Stage - I dissolved in water further reacts with Thiourea yields in to Di Hydrochloride compound which reacts with IF and caustic solution in presence of Methanol and water to yield crude Famotidine. Stage - IF

Sulfamide is reacted with Acrylonitrile in presence of HCl(g) and product is isolated by centrifuging and washed with Acetone. Stage _ IV

Crude Famotidine is purified in IPA / water to give Purified Famotidine. Stage – V

Once purified, Famotidine is dissolved in water and Acetic Acid and charcolised, filtered through Hyflow. To clear filtrate, liquor Ammonia ( 20% ) is added & adjusted pH 8.0 to get the pure Famotidine.

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Famotidine Process Flow Diagram With Consumption per Kg of Famotidine STAGE - I 1,3 Dichloro Acetone (0.588k) (3.53ltr.) Acetone Gunyl Thiourea (0.564k) (0.0235k) Potassium Iodide Acetone recovery( 3.176L) Residue To Solid Waste (0.5L)

St - I Hydrochloride Compound (1.03K) STAGE – II & III Methanol (5.647L) (0.77K) Caustic Flakes Thiourea (0.329K) (5.647L) Water IF (1.13K) Methanol-WaterRec( 6.47L) To ETP (6.97L) Crude Famotidine (1.117K)

S S R

S S R

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STAGE – IV (11.176L) IPA-water

Crude Famotidine (1.117K)

IPA-Water recovery( 10.88L) To ETP (0.35L)

Purified Famotidine (1.06K) STAGE - V

Liq. Ammonia (0.682L) Hyflow (0.03K) (0.34L) Acetic Acid (1.41L) Water (Make-up) Charcoal (0.053K)

Recycle (6.0L) Charcoal & Hyflow (0.082K) ML (8.5L) 2.5 L to ETP Pure Famotidine ( 1.0) STAGE - IF Acrylonitrile (2.058K) Sulfamide (0.588K) HCL-30% (11.76L) Acetone (0.588L) Acrylonitrile recovery( 1.476L) HCL-20% (11.76L) Acetone ( 0.53L) Vapour Loss ( 0.09L ) Intermediate Famotidine (1.13)

S S R

S S R

G L R

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PRODUCT : PREGABALIN

Brief manufacturing process : Stage-I

Salt formation of Hexanoic Acid with R(+) Phenyl ethyl amine by using Chloroform as a media. Isolate wet material by filtration and dry it. It is Pregabalin stage-I.

Stage-II

Breaking of salt (stage-I) by Hydrochloric acid using water as a media. Solid product isolate by filtration at low temperature. Dry this product and then purify in IPA.

Stage-III

Stage-II material is reacted with Bromine in presence of aqueous Caustic solution at lower temperature, then neutralised with Hydrochloric acid and it gives crude Pregabalin. Solid product is isolated by filtration and then dried.

Stage-IV

Purification of crude material in IPA-water mixture with giving charcoal treatment at higher temperature. Precipitate solid at lower temperature and isolate it by filtration. Dry the wet material in dryer. This is final Pregabalin.

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Flow diagram of Pregabalin Stage-I ( all quantities are in Kg ) Chloroform: 77.5 Kg RBF Hexanoic acid(R/S): 4.76 Kg Resolution

R(+)PEA(2.23 Kg) reaction

Reaction mass

Chloroform: 7.0 Kg

Filtration CHLROFORM: 82.13 Kg

recovered and reused

Drying wet cake:5.23 Kg Drying loss: 1.71 Kg Stage-I Dry material: 3.52 Kg S-Salt Stage-II Stage-I: 3.52 Kg RBF Water: 10.57 Kg Salt breaking HCl: 1.11 Kg Reaction water: 2.44 Kg Filtration water : 14.797 Kg HCl: 0.057 Kg To ETP as liquid effluent

Drying wet cake: 2.90 Kg Drying loss: 0.83 Kg

Stage-II crude Dry material: 2.07 Kg

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Stage-II : Purification: Stage-II Crude: 2.07 Kg RBF IPA: 2.46 Kg Purification IPA: 0.11 Kg Filtration IPA ML: 2.74 Kg

For recovery of IPA

Drying wet cake: 1.9 Kg Drying loss: 0.19 Kg Stage-II Pure Dry material: 1.71 Kg S-isomer

Stage-III (Crude formation) Water 8.57 Kg RBF Sodium 3.57 Kg Hoffman Bromide Solution Stage-II 1.71 Kg Reaction HCl 2.74 Kg Filtration ML+WML: 16.09 Kg Water 0.85 Kg Liquid effluent to ETP

Drying wet cake: 1.35 Kg Drying loss: 0.18 Kg Stage-III Crude Dry material: 1.17 Kg Crude

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Stage-IV (Purification) RBF Stage-III 1.17 Kg Purification IPA 9.53 Kg Water 4.04 Kg Charcoal 0.057 Kg Filtration Solid : Charcoal: 0.057 Kg Hyflow 0.09 Kg Hyflow: 0.09 Kg IPA 0.55 Kg Water 0.23 Kg Precipitation IPA 0.87 Kg Filtration IPA -WATER: 15.51 Kg Water 0.29 Kg For IPA recovery Drying wet cake: 1.17 Kg Drying loss: 0.17 Kg Stage-IV Pure Dry material: 1.0 Kg Pregabalin

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PRODUCT : DI BENZOYL LACTUM Brief Process :- Stage – I

D- Mannitol is charged in mixture of 2, 2 Dimethoxy Propane and Di – Methyl Sulfoxide. PTSA is added as a catalyst to the mixture. After maintaining reactor mass, solid product is isolated by adding N - Hexane & Ethyl Acetate. The obtained solid is dissolved in Di- Chloro Methane & reacted with Sodium meta Periodate to get the Stage – I. Stage – II

Stage – I is dissolved in the THF and reacted with Zinc Dust and Ethyl Bromo Di Fluoro Acetate in presence of Tri Methyl Chloro Silane. Product is extracted in Ethyl Acetate & washed with Sodium Chloride & Bi carbonate solution. Stage – III

Liquid residue of Stage- II product is dissolved in Acetonitrile, reacted with Trifluro Acetic Acid & water after removal of Acetonitrile Pyridine and 4-Di Methyl Amnino Pyridine is added. Obtained product is extracted in Ethyl Acetate, washed with Sodium Chloride & Sodium Bi Carbonate product is isolated by adding Di Chloro Methane & n - Hexane as Di Benzoyl Lactum dried in try.

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Di – Benzoyl lactum Process Flow Diagram Stage – I

Stannous Chloride (0.005K) Ethyl Acetate (30L) N – Hexane (21.5L) Di- Methyl Sulfoxide (4.5L) Sod Meta per Iodate (2.8K) Di-Chloro Methane (20L) D- Manitol (2.5K) Water (10.00L) 2-2 Dimethoxy Propane (4.4L) Hyflow ( 0.15K) . Charcoal(0.05K) N-Haxane ( 18.75L) Ethly Acetate ( 26.25L) Di-Chloro Methane ( 17.5L) Vapour Loss ( 2.85K) Liq-Effluent to ETP (28.75L) Charcoal & Hyflow ( 0.2K) Stage – I ( 1.6K)

S S R

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STAGE-II ST- I (1.6K)

HCL (1.55L) TMCS (0.0075) Ethyl Acetate (18L) Soda Bicarbonate (0.265K) EBDFA (1.8K) THF (15.5L) Water ( 25L) Sod. Chloride (4.185K)

Liquid Effluent to ETP (36.56L) THF( 13.75L) Ethyl Acetate ( 15L)

Stage – II (2.6K)

S S R

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STAGE-III Stage –II ( 2.6K)

Pyridine (2.3L) Toluene (11L) 4 DMAP (0.3125K) Ethyl Acetate (23.75K) Benzoyl Chloride (3.15K) Water (10.00L) Trifuloro Acetic Acid (0.3125K) Di – Chloride Methane (7.25L) N- Hexane (10L) Acetonitrile (20L) NACL (0.1837) Charcoal (0.25K)

HCL (0.8L) Hyflow (0.25K)

Sod. Bi- Carb. (0.39K) Tolune ( 10L) Etyl Acetate ( 21.25L)

Liquid Effluent to ETP (29.30L) N-Haxane (8L) Acetonitrile (18L) Di-Choloro Metahan(5L) Stage – III ( Di Benzoyl Lactum ) (1K)

SSR

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PRODUCT : LIGNOCAIN HCL Brief Process

Lignocain Crude base is dissolved in Acetone water, Charcolised & to the clear SOP HCl is added to get Lignocain HCl.

Lignocain HCl Process Flow Diagram

Lignocain Base (0.93) Acetone (2.0) HCL (1.0) Charcoal & Hyflow (0.1) Acetone Recovery ( 1.85 ) Charcoal & Hyflow (0.1) To ETP (1) Residue to ( 0.08 ) Solid wastes Lignocain HCL ( Approx. 1.0Kg)

S S R

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ANNEXURE – 3

DETAILED SPECIFICATIONS OF INCINERATOR

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ANNEXURE – 4

GA DRAWING OF SCRUBBER

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ANNEXURE – 5

MEMBERSHIP CERTIFICATE OF TSDF SITE

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ANNEXURE – 6

NATIONAL AMBIENT AIR QUALITY STANDARDS

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NATIONAL AMBIENT AIR QUALITY STANDARDS ( NAAQS ) ( 2009 )

Sr. No.

Pollutant Time Weighted Average

Concentration In Ambient Air Industrial, Residential,

Rural & Other Area

Ecologically Sensitive

Area (Notified by

Central Govt.)

Methods of Measurement

1 Sulphur Dioxide (SO2), ug/m3

Annual *

24 hours **

50

80

20

80

• Improved West & Gaeke

• Ultraviolet fluorescence

2 Nitrogen Dioxide (NO2), ug/m3

Annual *

24 hours **

40

80

30

80

• Modified Jacab & Hochheiser (Na-Arsenite)

• Chemiluminescence 3 Particulate Matter (size

less than 10 um) or PM10, ug/m3

Annual *

24 hours **

60

100

60

100

• Gravimetric • TOEM • Beta attenuation

4 Particulate Matter (size less than 2.5 um) or PM2.5, ug/m3

Annual *

24 hours **

40

60

40

60

• Gravimetric • TOEM • Beta attenuation

5 Ozone(O3), ug/m3 8 hours **

1 hour **

100

180

100

180

• UV photometric • Chemiluminescence • Chemical method

6 Lead (Pb), ug/m3 Annual *

24 hours **

0.50

1.0

0.50

1.0

• AAS/ICP method after sampling on EPM 2000 or equivalent filter paper

• ED – XRF using Teflon filter

7 Carbon Monoxide (CO), ug/m3

8 hours *

1hour **

02

04

02

04

• Non-dispersive Infrared (NDIR) spectroscopy

8 Ammonia (NH3), ug/m3 Annual *

24 hours **

100

400

100

400

• Chemiluminescence • Indophenol blue method

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9 Benzene (C6H6), ug/m3 Annual * 05 05 • Gas Chromatography based continuous analyzer

• Adsorption & Desorption followed by GC analysis

10 Benzo(a) Pyrene(BaP) – Particulate phase only, ug/m3

Annual * 01 01 • Solvent Extraction followed by HPLC/GC analysis

11 Arsenic (As), ug/m3 Annual * 06 06 • AAS/ICP method after sampling on EPM 2000 or equivalent filter paper

12 Nickel (Ni), ug/m3 Annual * 20 20 • AAS/ICP method after sampling on EPM 2000 or equivalent filter paper

* Annual arithmetic mean of minimum 104 measurements in a year at a particular site taken twice a week 24 hourly at uniform intervals. ** 24 hourly or 08 hourly or 01 hourly monitored values, as applicable, shall be complied with 98 % of the time in a year. 2% of the time, they may exceed the limits but not on two consecutive days of monitoring. Note : Whenever and wherever monitoring results on two consecutive days of monitoring exceed the limits

specified above for the respective category, it shall be considered adequate reason to institute regular or continuous monitoring and further investigation.

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ANNEXURE – 7

DRINKING WATER STANDARDS

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INDIAN STANDARDS FOR DRINKING WATER IS : 10500, 1991 Sr. CHARACTERISTICS REQUIREMENT UNDESIRABLE PERMISSIBLE No. (DESIRABLE) EFFECTS OUTSIDE LIMIT IN

THE DESIRABLE LIMIT ABSENCE OF

ALTERNATE

SOURCE 1) Colour, Hazen units 5 Above, consumer 25 acceptance decreases

2) Odour -- Unobjectionable --

3) Taste -- Agreeable --

4) Turbidity, NTU 5 Above, consumer 10 acceptance decreases

5) pH Value 6.5 to 8.5 Beyond this range, the No relaxation water will affect the mucous membrane and / or water supply system

6) Total Hardness, 300 Encrustation on water 600 mg / L as CaCO3 supply structure and adverse effects on domestic use

7) Iron, mg / L ( as Fe ) 0.3 Beyond this limit, taste / 1 appearance are affected. Has Hadverse effect on domestic uses and water supply structures structures & promotes iron bacteria

8) Chlorides, mg / L ( as Cl ) 250 Beyond this limit, taste, 1000 corrosion and palatability are affected

9) Residual Free 0.2 -- -- Chlorine, mg / L

10) Total Dissolved 500 Beyond this, palatability 2000 Solids, mg / L decreases and may cause gastrointestinal irritation

11) Calcium, mg / L ( as Ca ) 75 -- 200

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INDIAN STANDARDS FOR DRINKING WATER IS : 10500, 1991 (contd.)

Sr. CHARACTERISTICS REQUIREMENT UNDESIRABLE PERMISSIBLE No. (DESIRABLE) EFFECTS OUTSIDE LIMIT IN

THE DESIRABLE LIMIT ABSENCE OF ALTERNATE SOURCE 12) Copper, mg / L ( as Cu ) 0.05 A stringent taste, discoloration 1.5

of pipes, fitting and utensils will be caused beyond this

13) Manganese, mg/L (as Mn) 0.1 A stringent taste, discoloration 0.3 of pipes, fitting and utensils will be caused beyond this

14) Sulphates, mg / L as SO4 200 Beyond this causes 400 gastrointenstinal irritation when Magnesium or Sodium are present

15) Nitrates, mg / L as NO3 45 Beyond this, 100 methaemoglobinemia

16) Fluoride, mg / L (as F) 1 Fluoride may be kept as low 1.5 as possible. High Fluoride may cause Fluorosis

17) Phenolic Substances 0.001 Beyond this, it may cause 0.002 mg / L (as C6H5OH) objectionable taste and odour

18) Mercury, mg / L (as Hg) 0.01 Beyond this, the water becomes No relaxation toxic

19) Cadmium, mg / L (as Cd) 0.01 Beyond this, the water becomes No relaxation toxic

20) Selenium, mg / L (as Se) 0.01 Beyond this, the water becomes No relaxation toxic

21) Arsenic, mg / L (as As) 0.05 Beyond this, the water becomes No relaxation toxic

22) Cyanide, mg / L (as Cn) 0.05 Beyond this, the water becomes No relaxation toxic

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INDIAN STANDARDS FOR DRINKING WATER IS : 10500, 1991 (contd.)

Sr. CHARACTERISTICS REQUIREMENT UNDESIRABLE PERMISSIBLE No. (DESIRABLE) EFFECTS OUTSIDE LIMIT IN

THE DESIRABLE LIMIT ABSENCE OF

ALTERNATE

SOURCE 23) Lead, mg / L (as Pb) 0.05 Beyond this, the water becomes No relaxation

toxic

24) Zinc, mg / L (as Zn) 5 Beyond this limit, it can cause 15 stringent taste and an opalescence in water

25) Anionic Detergents 0.2 Beyond this limit, undesirable 1 mg / L (as MBAS) taste and odour after chlorination takes place

26) Chromium, mg / L as Cr+6 0.01 May be carcinogenic above this limit 0.05

27) Polynuclear Aromatic May be carcinogenic Hydrocarbons, mg / L (as PAH)

28) Mineral Oil, mg / L 0.01 Beyond this limit, undesirable 0.03 taste and odour after chlorination takes place

29) Pesticides, mg / L Absent Toxic 0.001

30) Radioactive Materials, a) Alpha emitters, Bq / L 0.1 b) Beta emitters, pci / L 1

31) Alkalinity, mg / L 200 Beyond this limit, taste 600 (as CaCO3) becomes unpleasant

32) Aluminum, mg / L (as Al) 0.03 Cumulative effect is reported 0.2 to cause dementia

33) Boron, mg / L (as B) 1 5

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ANNEXURE – 8

EFFLUENT DISPOSAL STANDARDS ( IS )

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INDIAN STANDARDS FOR INDUSTRIAL AND SEWAGE EFFLUENT DISCHARGE IS : 2490 - 1982

Sr. CHARACTERISTICS INTO INLAND ON LAND INTO INTO PUBLIC No. SURFACE FOR MARINE SEWERS

WATER IRRIGATION COASTAL AREA 1) Colour / Odour -- -- -- --

2) Suspended Solids, mg / L 100 200 100 (for Process 600 Waste)

3) Particle Size Suspended Solids Shall pass 850 µ -- Floatable Solids, -- (MPN / 100 ml), Max. IS Sieve Max. 3 mm Settleable Solids, Max 850 µ

4) Total Dissolved Solids (Inorganic) 2100 2100 -- 2100 (mg / L)

5) pH Value 5.5 to 9.0 5.5 to 9.0 5.5 to 9.0 5.5 to 9.0

6) Temeprature, o C Shall not exceed 40 in any -- 45 at the point of -- section of the stream within discharge 15 m. downstream from the effluent outlet

7) Oil & Grease, mg /L 10 (Max.) 10 (Max.) 10 (Max.) 20 (Max.)

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8) Total Residual Chlorine, mg / L 1.0 (Max.) -- 1.0 (Max.) -- 9) Ammonical Nitrogen (as N), mg / L 50 (Max.) -- 50 (Max.) 50 (Max.)

10) Total Kjeldahl Nitrogen (as N), mg / L 100 (Max.) -- 100 (Max.) --

11) Free Ammonia (as NH3), mg / L 5 (Max.) -- 5 (Max.) --

12) Biochemical Oxygen Demand, mg / L 30 100 100 350 5 days at 20 o C

13) Chemical Oxygen Demand, mg / L 250 (Max.) -- 250 (Max.)

14) Arsenic (as As), mg / L 0.2 (Max.) 0.2 (Max.) 0.2 (Max.) 0.2 (Max.)

15) Mercury (as Hg), mg / L 0.01 (Max.) -- 0.01 (Max.) 0.01 (Max.)

16) Lead (as Pb), mg / L 0.1 (Max.) -- 1.0 (Max.) 1.0 (Max.)

17) Cadmium (as Cd), mg / L 2.0 (Max.) -- 2.0 (Max.) 1.0 (Max.)

18) Hexavalent Chromium (as Cr+6), mg / L 0.1 (Max.) -- 1.0 (Max.) 2.0 (Max.)

19) Total Chromium (as Cr), mg / L 2.0 (Max.) -- 2.0 (Max.) 2.0 (Max.)

20) Copper (as Cu), mg / L 3.0 (Max.) -- 3.0 (Max.) 3.0 (Max.)

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21) Zinc (as Zn), mg / L 5.0 (Max.) -- 15 (Max.) 15 (Max.) 22) Selenium (as Se), mg / L 0.05 (Max.) -- 0.05 (Max.) 0.05 (Max.)

23) Nickel (as Ni), mg / L 3.0 (Max.) 5.0 (Max.) 3.0 (Max.)

24) Boron (as B), mg / L 2.0 (Max.) 2.0 (Max.) -- 2.0 (Max.)

25) Percent Sodium -- 60 (Max.) 60 (Max.) --

26) Residual Sodium Carbonate, mg / L -- 50 (Max.) -- --

27) Cyanide (as CN), mg / L 0.2 (Max.) 0.2 (Max.) 0.2 (Max.) 0.2 (Max.)

28) Chlorides (as Cl), mg / L 1000 (max.) 600 (max.) -- 1000 (Max.)

29) Fluorides (as F), mg / L 2.0 (Max.) -- 15 (Max.) 15 (Max.)

30) Dissolved Phosphates (as P), mg / L 5.0 (Max.) -- -- --

31) Sulphates (as SO4), mg / L 1000 (Max.) 1000 (Max.) -- 1000 (Max.)

32) Sulphides (as S), mg / L 2.0 (Max.) -- 5.0 (Max.) --

33) Phenolic Compounds (as C6H5OH), 1.0 (Max.) -- 5.0 (Max.) 6.0 (Max.) mg / L

Akshar Consultants


SPPL

34) Radioactive Materials a) Alpha Emitters, µc / ml 10 - 7 (Max.) 10 - 8 (Max.) 10 - 7 (Max.) 10 - 7 (Max.) b) Beta Emitters, µc / ml 10 - 6 (Max.) 10 - 7 (Max.) 10 - 6 (Max.) 10 - 6 (Max.)

35) Manganese (as Mn), mg / L 2.0 (Max.) 2.0 (Max.) -- 2.0 (Max.)

36) Iron (as Fe), mg / L 3.0 (Max.) 3.0 (Max.) -- 3.0 (Max.)

37) Vanadium (as V), mg / L 0.2 (Max.) -- 0.2 (Max.) 0.2 (Max.)

38) Nitrate Nitrogen, mg / L 18 20 -- 0.2

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SPPL

ANNEXURE – 9

AMBIENT NOISE STANDARDS

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SPPL

AMBIENT NOISE STANDARDS AS PER THE NOISE POLLUTION RULES, 2000

CATEGORY OF AREA Leq dB (A), Day Time Leq dB (A), Night Time (06:00 to 21:00 hours) (21:00 to 06:00 hours) Industrial Area 75 70 Commercial Area 65 55 Residential Area 55 45 Silence Zone 50 40

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SPPL

ANNEXURE – 10

OSHA NORMS FOR NOISE

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SPPL

DAMAGE RISK CRITERIA FOR HEARING LOSS

OCCUPATIONAL SAFETY & HEALTH ADMINISTRATION (OSHA)

MAXIMUM ALLOWABLE DURATION, NOISE LVEL, (dBA) HOURS / DAY (SLOW RESPONSE)

8 90 6 92 4 95 3 97 2 100

1.5 102 1 105

0.5 110 0.25 or less 115

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SPPL

ANNEXURE – 11

MAJOR INDUSTRIES IN STUDY AREA

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MAJOR INDUSTRIES IN THE STUDY AREA

1. ETC Agro Food Processing Pvt. Ltd., Vil. : Andhaj

2. Maxmech Equipments Pvt. Ltd., Vil. : Varsola

3. Amul Satellite Dairy – Vil. : Jibhaipura

In addition to the above stated major industries, the area houses few smaller units i.e. saw mills and other miscellaneous type of industries.

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SPPL

ANNEXURE – 12

RAIN WATER RECHARGE SCHEME

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DETAILS OF TYPICAL RAIN WATER RECHRGE SCHEME

Net increase in water requirement of the project is estimated to be approximately 4.0 KL per day and is proposed to be met through existing bore – well within the premises. Hence, to compensate for this withdrawal, a rain water harvesting and recharging scheme is proposed. The necessity to harness rainwater and to recharge the same into the ground water aquifer has been recognized. Hence, it is decided to harvest rain water from roofs and surface run – off from internal roads and open vacant space within the premises and recharge it. Rain water collected from roof tops and surface run – off will be suitably collected and conveyed to a central point where a suitable recharge structure will be constructed. Generally, it is economical to recharge directly existing open wells or tube wells but as there are no existing open wells or tube wells in the project site, new recharge pits are being proposed. The recharge structure should be such that its filter media can be easily taken out and washed so that clays deposited during filtration are removed to regain the original infiltration rate and reinstalled conveniently without much expenditure. Keeping this in view, recharge pits and recharge trenches are being proposed for this project. Initially, 1 no. of recharge pit cum filtration tank of size 2 mt. x 2 mt. x 3 mt. deep is proposed to be constructed within the premises with a tube well in the centre of the filtration pit. The tube well will have a slotted 200 mm dia. pipe which will extend upto the unsaturated zone of water. Recharging of ground water through these pit will be monitored and based on data of recharge, if required, more no. of similar recharge pits will be constructed within the premises. Roof top rain water from plant building of the project will be collected through 100 mm PVC drain pipes and will be taken to the recharge pit through PVC / MS pipe of suitable size. The recharge pit cum filtration tank will be provided with 0.90 mt. thick layer of pebbles (10 mm to 30 mm in size) at the bottom followed by 0.90 mt. thick layer of gravel (5 mm to 10 mm in size) followed by 0.90 mt. thick coarse sand (2 mm to 4.75 mm in size). At the top of the tank, a 0.30 mt. thick layer of pebbles or a layer of boulders (more than 30 mm in size) will be laid so that drain water does not disturb the coarse sand due to turbulence. The top of the tank will be slightly above the land surface so that silty surface water does not enter in the filtration tank. This tank will be lined with brick mortar or stone mortar (with cemented wall) but bottom portion will be exposed in sand or boulders.

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Any surplus water from the filtration tank will be taken as overflow to a recharge trench to be constructed along the side of the recharge tank. Both the width and depth of the trench will be kept as 1.0 mt. The trench will be unlined, filled at the bottom with 30 cm. thick layer of pebbles, 30 cm. thick layer of gravel, 30 cm. thick layer of coarse sand and 10 cm. thick layer of pebbles or one layer of boulders. An outlet of 100 mm. G.I pipe will be provided from the top of the filtration tank to the recharge trench in such a way that water gets filled all along the length of the trench. The water in the trench will gradually percolate and join the water table in due course of time. The length of trench will be suitably decided. Such an arrangement will maximize rain water recharge potential. Considering roof area of plant to be approximately 225 sq. mtrs. and assuming average annual rain-fall as 850 mm and 0.85 as runoff co-efficient for cemented roofs, Available roof water for recharge = 225 x 0.85 x 0.85 = 162 KL per year or say = 160 KL per year. Considering approximate road area and other open area of plant to be 1650 sq. mtrs. and assuming average annual rain-fall as 850 mm and 0.75 as runoff co-efficient for road and other open area, Available water for recharge = 1650 x 0.75 x 0.85 = 1052 KL per year or say = 1050 KL per year. Thus, total quantity of water that can be recharged per year = 160 + 1050 = 1210 KL per year This figure meets the total per year additional ground water withdrawal of 1200 KL (4.0 KL per day x 300 no. of working days per year). Typical cross – section of recharge pit is presented in figure below.

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SPPL

ANNEXURE – 13

LIST OF PERSONAL PROTECTIVE EQUIPMENTS

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SPPL

LIST OF PERSONAL PROTECTIVE EQUIPMENTS TO BE PROVIDED IN PLANT

Protection for Equipment Protection Against Indian Standards

Head Helmet

Fall of objects/hitting against objects during construction, maintenance, etc.

IS 2925 : 1984

Eye Leather mask goggles Foreign bodies entering the eyes and smoke. IS 5983 : 1980

Spectacle type goggles with plain shatter proof lens

Foreign bodies entering the eyes and reflected arc rays.

IS 1179 : 1967

Panorama goggles with green plastic vision

Reflected arc rays during arc welding job. IS 1179 : 1967

Ear Ear plugs or muffs High noise level. IS 8520 : 1977

Nose Dust respirators Fine dust particles. IS 9473 : 1980

Light fume mask

Acid fumes, vapors and gases (2.0%). IS 8522 : 1977

Canister gas mask Acid fumes, vapors and gases (2.0%). IS 8523 : 1977

Face Plastic face shield Liquid chemicals, dust particles. IS 8940 : 1978

Welding helmet and shield Welding fumes, sparks and UV rays. IS 8521 : 1977

Body Leather apron Falling of hot chips, slogs, etc. IS 818 : 1968

PVC apron Splashing of chemicals. IS 4501 : 1981

Safety belt Falling of persons from height. IS 3521 : 1983

Hand Acid and Alkali proof rubber gloves

Burns due to chemical handling. IS 2573 : 1986

Electrical resistance gloves Electric shock. IS 4770 : 1968

Canvas gloves Contact with oil, grease, etc. IS 6994 : 1973

Leg Leather safety boots

Striking by objects, fall of objects and stepping on sharp or hot objects.

IS 1989

Ankle boot for general purposes stepping on hot or sharp objects, striking by stationary or moving objects.

IS 583 : 1981

Gum boots Liquid splashing in submerged area and chemically hazardous area.

IS 5557 : 1969

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SPPL

ANNEXURE – 14

COMPLIANCE OF CREP GUIDELINES

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SPPL

PHARMACEUTICALS

Sr. No. Action Point

Compliance

01. Segregation of waste stream Waste streams should be segregated into high COD waste, toxic waste, low COD waste, inorganic waste etc. for the purpose of providing appropriate treatment

Concentrated process stream, scrub liquor effluent, softening plant regeneration water, cooling tower blow – down etc. will be incinerated in in – house incinerator. Solvents will be recovered in solvent recovery unit and recycled back to process. Distillation residue will be segregated and sent to BEIL for incineration or in in – house incinerator.

02. Detoxification and treatment of high COD High COD streams should be detoxified and treated in ETP or thermally destroyed in incinerator.

Concentrated process effluent stream and scrubber effluent will be incinerated in in – house incinerator. Similarly, distillation residue will be sent to BEIL for incineration or in in – house incinerator.

03. Management of solid waste Proper facilities should be provided for handling and storage of hazardous waste. For final disposal of hazardous waste, recycling and reuse should be given priority, either within the premises or outside with proper manifest system. In case of incinerable waste, properly designed incinerator should be installed within the premises or outside as a common facility. The non-incinerable hazardous waste should be disposed of in properly designed secured landfill either within the industry’s premises or in a common facility.

Separate solid waste storage area having impervious bottom, pucca roof and leachate collection system has been provided. Leachate, if any, will be taken to ETP for treatment and disposal. All hazardous wastes will be separately stored at this site in appropriate container. ETP sludge and spent carbon / hyflow etc. will be disposed off into TSDF of NEPL. Distillation residue will be sent to common incineration facility of BEIL or in in – house incinerator. Used oil will be given to CPCB registered re-processor of oil and discarded containers will be given to registered vendor after decontamination. Unit has already taken membership of TSDF of NEPL.

04. Minimum scale of production to afford cost of pollution control For new industries which are not connected with CETP & TSDF and which do not have the economics to install treatment facilities may not be considered for granting consent to establishment. Industry association shall submit proposal to SPCB / CPCB

Unit already has an in-house ETP cum incinerator for treatment of all effluent streams. For disposal of hazardous wastes it has become member of TSDF of NEPL.

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05. Long term strategies for reduction in waste Consent for establishment and consent for operation under Water Act will be based on pollution load and concentration of pollutants. Each industry will submit pollution load, concentration of final discharge alongwith water balance to SPCB/CPCB for formulation of strategy

Necessary details will be provided to GPCB at appropriate stage of project implementation. Unit will strive to reduce pollution load through optimum utilization of resources like raw material etc.

06. Control of air pollution Industry will take up on priority, the control of hazardous air pollutants (such as benzene, carbon tetrachloride, 1-4 dioxane, methanol, toluene, methyl chloride etc.) and odorous compounds (mercapatan & hydrogen sulphide)

Minimum inventory of raw materials will be kept. Handling / transfer of Solvents will be by metering pumps to minimize loss to atmosphere. Cooling and chilled water / brine will be passed through condensers installed on reactors to control fugitive emission of VOC. Received solvents will be sent back to process and condenser vents will be attached to scrubber to further minimize chance of solvent vapours being released into the atmosphere.

07. Self Regulation by Industry though regular monitoring and environmental auditing Industries on their own will carry out monitoring of environmental parameters, audit it in regular interval and submit the same to SPCB. Comment of BDMA - There will be a policy for accreditating the auditors and the policy guidelines may be issued by the MoEF.

All applicable environmental parameters will be regularly monitored as per the environmental monitoring plan devised by the unit. Environmental Statement (in Form-V) will be regularly submitted to GPCB.

08. Oranisational restructuring and accreditation of Environmental Manager of Industry (a) Environment management cell will be created for each industry reporting to CEP directly. (b) There should be a certification system for the environmental managers at individual level and common facility level. BDMA may evolve the programme alongwith SPCB/CPCB

Company will set-up an Environment cell consisting of well-qualified and experienced professionals from the field of safety and environment. Company will endeavour to obtain ISO : 14001 certification.

09. Optimising the inventory of hazardous chemicals The information shall be submitted to SPCB regularly alongwith rational

All rules and regulations of Factory Inspectorate will be complied with. On-site emergency plan will be prepared based on risk assessment study and strictly implemented. All details will be submitted to all concerned authorities as per MSIHC Rules.

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SPPL

ANNEXURE – 15

BRIEF PROFILE OF CONSULTANT ENGAGED FOR REIA STUDY

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PROFILE OF CONSULTANTS ENGAGED FOR EIA STUDY

CONSULTING FIRM : AKSHAR CONSULTANTS ADDRESS : 813, SAKAR – 5, NEAR MITHAKHALI RAILWAY CROSSING, OFF ASHRAM ROAD, AHMEDABAD 380 009, GUJARAT. TEL. NO. : 079 – 26583525 FAX NO. : 079 – 26583525 E MAIL : [email protected] PROMOTER’S NAME : MR. DARSHAN PAREKH. B. E. ( ENV. ENG. ) PROMOTER’S EXPERIENCE :

More than 20 (Twenty) years of experience in the field of Environment Management System ( EMS ) and pollution control of various industries like chemical, dyes and dyes - intermediates, textiles, pharmaceuticals, rolling mills, cement etc. i. e. design, commissioning and operation of small to very large ETPs, carrying out of EIA studies, air pollution control systems, treatability studies, environmental audits etc.

ADDITIONAL INFORMATION : Organisation has in-house laboratory facility equipped with all necessary instruments / equipments / glassware etc. required for testing of pollution parameters ( water / effluent / gaseous emission / solid wastes / soil / noise etc. ) and to carry-out EIA studies. Adequate human resources having requisite qualification and experience is retained and forms part of a young and dedicated team of professionals.

REGISTRATIONS : Akshar Consultants is registered with GPCB, Gandhinagar as “Recognised Schedule–II Environmental Auditor “ and has also submitted its’ application to NABET / QCI, New Delhi for accreditation as EIA consultant organization.

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SPPL

LIST OF PERSONS INVOLVED IN THIS ASSIGNMENT

SR. NO.

NAME DESIGNATION QUALIFICATION

1 Shri Darshan Parekh Proprietor B.E. ( Env. )

2 Shri Gopal Deware Chemical Engineer B.E. ( Chem. )

3 Shri Virpalsinh Chavda Chemist B.Sc. ( Chemistry )

4 Ms. Ashita Bhavsar Microbiologist B.Sc. ( Microbiology )

5 Ms. Shefali Khatri Sr. Computer Analyst B. Com., DCT

6 Dr. Manoj Eledath Technical Associate M.Sc., Ph.D.

7 Shri Prakash Vaghela Technical Associate B.E. ( Env. )

8 Shri Sundeep Shah Technical Associate B.E. ( Env. )

9 Shri Chandrashekhar Vaidya

Technical Associate B.E. (Electronics), M.E. (Computer Appl.)

10 Shri Kaushik Pandya Field Supervisor H.S.C.E.

11 Skilled and semi – skilled field staff

--- ---

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SPPL

ANNEXURE – 16

UNDERTAKING BY PROJECT PRAPONENT

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chapter 4 environmental impact …gpcb.gov.in/pdf/swana_pharma_eia_part_2.pdfakshar consultants reia...

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