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Chapter – 7
Environmental Risk Assessment (ERA)
And
Disaster Management Plan (DMP)
7.1 Public Consultation
The details of Public Consultation have been conducted and the details of which have been
enclosed as AnnexureVII.
7.2 Risk Assessment
Risk Assessment, on site Emergency Preparedness & Disaster Management Plan It is presumed
that the proposed facilities for expansion would be designed and engineered with all possible
safety measure and standard code of practices of engineering. In spite of this, there may be
some design deficiency or due to operation and maintenance faults which may lead to
accidental events causing damage to life and property. This Chapter presents an overview of
environmental risk associated with various production facilities, suggested remedial measures
and an outline of the emergency preparedness plan.
The objectives of environmental risk assessment are governed by the following, which excludes
natural calamities.
To identify the potential hazardous areas so that necessary design safety measures can
be adopted to minimize the probability or accidental event.
To identify the potential areas of environmental disaster this can be prevented by proper
design of the installations and its controlled operation.
To manage the emergency situation or a disastrous event, if any, from the plant
operation.
Managing a disastrous event will obviously require prompt action by the operators and the crisis
management personnel using al their available resources like alerting the people and other plant
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personnel remaining inside, deployment of the fighting equipment, operation of emergency shut
off valves, opening of the escape doors, rescue etc.
Minimizing the immediate consequences include cordoning off, evacuation, medical assistance
and giving correct information to the families of the affected persons and local public for
avoiding rumors and panic.
Lastly, an expert committee is required to probe the cause of such events and the losses
encountered, and suggested remedial measures for implementation, so that if future such
events or similar events do not reoccur.
7.3 Identification of hazards
The hazards are attributable due to processing of raw materials and chemicals used in
steelmaking and the other plant operations. A list of major raw materials used in the plant and
the process units with their hazard potential is presented below.
Group Item Hazard Potential
Remarks
Raw materials & Products
Iron ore None -
Coal Moderate Fire
Other fluxing minerals
None -
Product steel None -
Lube oil Moderate Flammable
Processing
Iron making in Rotary kiln
Coal reduction fuel gas
Major Flammable and CO pollution
Hot Metal Major Personnel injury & fire
Burning coal Major Personnel injury & fire Rolling Mills Hot metal Major Fire Utilities
Fuel gas Distribution Gas leaks Major Fire and CO pollution
Electric power supply Short circuit Major Fire
Transformer Small Explosion & fire
Power Plant
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From the above table, it may be observed that major on-site emergency situation may occur
from the organic coal, and handling, fuel gas handling, molten metal and slag handling, and
electrical short-circuits. The off-site environmental disaster may occur if large scale fire and
explosion occurs, the effect of which extends beyond the plant boundary. The off-site
environmental disaster may occur due to significant environmental degradation prolonged
for a sustained period.
7.4 HAZOP Study
It is suggested to have HAZOP study for the fuel gas distribution network handling facilities prior
to commissioning, for last minute corrections in the design of the systems from fail safe angle.
The HAZOP analysis for the gasholder has been carried out for safe operations.
The degree of Hazard is identified based on FEI and TI range as per the criteria given below.
Steam turbine generator building
Moderate Fires in Lube oil system, Short circuit in control room/switch gear, cable galleries & oil drum storage.
Boilers Heat recovery boilers
Moderate Fire/steam explosion
Coal Handling plant Normal weather condition with shed
Moderate Fire or dust explosion
Coal Storage Normal weather condition with shed
Moderate Spontaneous combustion
FEI Range Degree of Hazard
0-60 Light
61-96 Moderate
97-127 Moderately High
128-158 Heavy
159 & above Severe
TI Range Degree of Hazard
0-5 Light
5-10 Moderate
>10 Severe
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The storage of fuel oil/HSD is of a small quantity & may have light degree of hazard.
7.5 Electrical safety
Adequately rated and quick response circuit breakers, aided by reliable and selective digital or
microprocessor based electromagnetic protective relays would be incorporated in the electrical
system design for the proposed activities. The metering and instruments would be of proper
accuracy class and scale dimensions.
7.6 Risk Management measures
The risk management measures for the proposed activities require adoption of best safety
practice at the respective construction zones within the works boundary. In addition, the design
and engineering of the proposed facilities would take into consideration of the proposed
protection measures for air and water environmental as outlined in earlier Chapter. The detailed
risk management measures are listed below.
7.6.1 Coal Handling Plant
Coal dust when dispersed in air and ignited will explode. Crusher houses and conveyor are most
susceptible to this hazard. The minimum of explosive concentration of coal dust (33% volatiles)
is 50 grams/M3. Failure of dust extraction & suppression systems may lead to abnormal
conditions and increasing the concentration of coal dust to the explosive limits. The sources of
ignition are incandescent bulbs, electric equipments & cable, friction & spontaneous combustion
in accumulated dust. Dust explosion may occur without warning with maximum explosion
pressure upto 6.4 bars. Another dangerous characteristic of dust explosions is that it sets off
secondary after of initial dust explosion. Stack pile area shall be provided with automatic garden
type sprinklers as well as to reduce spontaneous ignition of coal stocks piles, necessary water
distribution net work will be provided for distributing water at all transfer points, crusher
houses, control room, etc.
A centralized control room has been envisaged for operation of the coal handling plant. Except
locally controlled equipment like traveling tripper, dust extraction/dust suppression/ventilation
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equipment, sump pumps, water distribution system all other in line equipment will be provided
for safe and reliable operation of the coal handling plant.
7.6.2 Control measures for coal yard
The entire quantity of coal will be stored in separate stack piles, with proper drains around to
collect washouts during the monsoon. Water sprinkling system will be installed on stocks of pile
to prevent spontaneous combustion and consequent fire hazards. The stack geometry will be
adopted to maintain minimum exposure of stock pile areas towards predominant wind
direction. Temperature will be monitored in the stock piles regularly to detect any abnormal
change in temperature inside the stock pile to be enable to control the same.
7.6.3 Induction Furnace
Preventive Measures
If any job is to be undertaken in furnace areas where the gas is toxic, the following procedure
has to be laid down to ensure safety of men and the equipment.
Gas safety man would accompany the team and would test the atmosphere for the
presence of CO, before starting the work.
If CO, concentration is found exceeding the sage limit, the job would be undertaken using
necessary safety appliances viz., Oxygen Breathing Apparatus/Blower type Gas mask.
Any gas cutting /welding job would be undertaken with the clearance from Gas safety
man.
7.6.4 Gas Explosion, Prevention & Preventive Measure
The following actions would be taken to prevent any gas explosions in case of gas leakage.
For jobs on gas lines/equipment, non-sparkling copper tools will used. If such tools are
not available, grease coated steel tools would be used. Electrical drill & other electrical
equipment will not be used as these can give rise to sparks.
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The gas line would be thoroughly purged with steam before undertaking the job on the
same.
Naked lights will not be used near any de-pressurized gas main or equipment unless the
same has been thoroughly purged.
In case of profuse leakage of gas, action would be taken for water sealing and isolating
that portion.
The approach road to the gas line complex would be kept free from any obstructions.
If gas catches fire due to some leakage, it will be extinguished with plastic clay, steam or
water. The portion of gas main affected would be cooled down with water. The valve will
not be closed when fire is still there and the pressure in the main will be maintained at
minimum 100mm (WC).
Gas tapping points of flow or pressure measurement will be cleaned with wooden stick
or grease coated wire.
If lighting is necessary near gas line, portable spark, proof electrical lamps of low voltage
or explosion proof torchlight will be used for enclosed areas.
7.6.5 Hot Metal
Sudden break out of molten metal result in heavy explosions, due to their coming in contact
with water, thereby causing serious burn injuries to persons and damage to equipment. These
breakouts may take place from weak portions of the health, tuyeres & monkely.
Preventive Measures
Any accumulation of water will be prevented in such vulnerable areas.
In case of minor leakages, the flow of molten metal & slag will be controlled.
If there is major breakout, the area would be cut off and cordoned.
Vital connections e.g. water, gas, compressed air, oxygen etc., would be cut off or regulated as
per requirement.
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7.6.6 Steel Melting Shop
The main hazards arise out of the use of hot metal and oxygen at the spillage of hot metal cause
serious burn injuries and fires. Severe explosions are also caused due to hot metal /slag falling
over a pool of water, resulting in injuries to persons, fire and damage to equipment due to flying
of hot splinters & splashing of liquid metal/slag.
7.7 Objective of the Plan
The emergency plan has been prepared to ensure the smooth working of the steel plant
complex. The main objectives of the plan are to take immediate actions to meet any emergency
situation making maximum use of combined in plant and allied resources for the most effective,
speedy and efficient rescue and relief operations. These are briefly enumerated below.
Cordon and isolate the affected are for smooth rescue operation.
Rescue and treat causalities and safeguard the rest.
Minimize damage to persons, property and surroundings
Contain and ultimately bring the situation under control
Secure and safe rehabilitation of the affected area
Provide necessary information to statutory agencies
Provide authoritative information to statutory agencies
Ward off unsocial elements and plying onlookers.
Counter rumor mongering and panic by relevant accurate information.
7.8 Methodology
Keeping in mind the detailed information on the proposed steel plant, the plan is formed on the
following basis:
Identification of possible hazards in various units and their impact on the surroundings.
Detailed information on the available resources and control measures.
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7.9 Industrial Safety and Fire Fighting
As detailed above, many working premises of the plant have hazardous and fire — prone
environment. To protect the working personnel and equipment from any damage or loss and to
ensure uninterrupted production, adequate safety and fire fighting measures have been
proposed for the project.
7.10 Safety plan during Construction & Erection Phase of Expansion
A highly qualified and experience Safety Officer will be appointed. The responsibilities of the
safety officers include identification of the hazardous conditions and unsafe acts of workers and
advice on corrective actions, conduct safety audit, organize training programmes and provide
professional expert advice on various issues related to occupational safety and health.
7.10.1 Safety Personnel
All workmen employed in hazardous working conditions will be provided with adequate
personal safety appliance as applicable to the work like:
Industrial helmets
Industrial safety boots
Hand gloves
Ear muffs
Welder's screen and aprons
Gas masks
Respirators
Resuscitators
7.10.2 Fire Protection facilities
Keeping in view the nature of fire and vulnerability of the equipment and the premises, the
following fire protection facilities have been proposed for the plant.
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7.10.3 Portable Fire Extinguishers
All plant units, office buildings, stores, Laboratories, MCCs etc. will be provided with adequate
number of portable fire extinguishers. The distribution and selection of extinguishers will be
done in accordance with the requirement of fire protection manual of Tariff Advisory Committee
(TAC).
7.10.4 Hydrant System
Hydrants will be provided in the coal handling plants at suitable locations and in different levels
inside the plant buildings. Yard hydrants will be provided in the vicinity to meet the additional
requirement of water to extinguish fire.
7.10.5 Automatic Fire Detection System
Unattended vulnerable premises like electrical control rooms, cable tunnels, MCC, oil cellars,
etc. will be provided with automatic fire detection and alarm systems.
7.10.6 Manual Call Point Systems
All major units and welfare/administrative building will be provide with manual call points for
summoning the fire fighting crew from the fire station for necessary assistance.
7.10.7 Fire Station
The Rosvar is going to provide elaborate arrangements for managing any incidents of fire with
adequate communication facilities. There will be sufficient fire tenders to extend the necessary
assistance required for fighting fire in any of the plant units and associate premises with
requisite augmentation. The following equipment will be provided in the fire posts.
Water tender
Foam tender
Portable pump
Wireless set
Hoses
Hot line telephone, etc.
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7.10.8 Plant Disaster Control
The Onsite emergency plan is prepared considering all the different units of the proposed steel
plant complex.
7.10.9 Organization
A Central Disaster Control Cell will be set up under the direct charge of the General Manager of
the project. He will be the person nominated to declare any major emergency and would be in-
charge of all operations in such situations. In his absence, Manager Works would be the in
charge. He will be supported by the other nominated members of cell, Engineer„ SMS & Mill.
Personnel, Security, Fire and safety, Administration. In case of any major emergency, the
Disaster Control Cell would operate from Disaster Control Room. At the shop level, Shift in
charge will be nominated as controller who will be assisted by trained key workers to deal with
any minor emergencies arising at the shop.
7.10.10 Information flow
The following guidelines will be observed by any person after noticing a gas leak, fire etc. till help
is made available from Central Disaster Control Cell.
Raise alarm
Communicate to the control room about the incident/emergency.
Communicate to fire station for relief in case telephone is available otherwise try to
attract attention by any available means.
Attempts to close doors, windows or ventilators of the room to prevent any
contaminated air getting in.
7.10.11 Central Disaster Control Room
Upon receiving information from any site regarding emergency, the person operating from the
Disaster Control room will.
Depute a person to rush to site and assess the situation.
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Inform fire transport, safety, and concerned control room.
Organize operating personnel and arrange for control over the situation.
Keep the management informed about the gravity of the situation from time to time.
On receiving the call, the Disaster Control room would immediately direct the different
supporting service agencies as enumerated below.
Security and Administration Service: responsible for safety of the plant against
trespassers, saboteurs, any crowd, information to Government authorities and in the
neighborhood (if required), provision of transport facilities, telecommunication facilities
and fire service facilities.
Safety service: responsible for implementation of safety measures at work place and
occupational safety.
Medical service: responsible for providing medical care to the injured or the affected in
an event of emergency. The visiting Doctor will be surrounded to the site to take charge
of medical care to employees.
Stores: responsible for providing adequate number of tools, tackles and accessories for
proper emergency control.
Preservation of evidence and taking of photographs, if necessary, for future enquiries to
determine the cause and taking further preventive actions.
Welfare: Provide food, clothes, shelter etc., as per requirement.
Power and water supply: to ensure supply of fire fighting water requirement and
provisions of power supply.
7.10.12 Shop Level Disaster Control Cell
The controller at the shop level would take immediate charge of any emergent situation and
would assume full responsibility regarding mobilization of resources, guide and help service
agencies in properly carrying out their assigned duties. Being from the operations side of the
plant, he has full knowledge of the process aspects and he would decide whether to stop the
plant/process. He will be responsible for overall co-ordination. In his absence, his Deputy would
be Controller of the operations. The duties of the Shop level Controller are enumerated below:
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Assess the scale of emergency and decide, if any possibility of major emergency exists
and inform the Central Control Room, if necessary.
Direct safe close down of plant or any operation, if necessary.
Direct evacuation of areas in the vicinity, which may be endangered.
Ensure key personnel are called in immediately and they start carrying out their assigned
duties.
Direct rescue and fire fighting operations from safe operation point of view.
Direct the shop personnel to the designated places for safe assembly.
Control rehabilitation of affected areas and any victim on emergency.
Ensure complete safety before restating the plant/operation.
At shop floor, teams of workers will be trained, who will be present at the incident site for doing
the needful; they will assist and extend help.
in controlling fire.
In shutting down plant to make it safe.
Search, evacuation, rescue team.
Movement of vehicles for emergency control.
Plant pollution monitoring staff for carrying out atmospheric tests. Medical team for
providing necessary help.
Any other special operation.
7.10.13 Contingency Plan
It has been based on the following considerations:
The plant general layout.
The available resources.
The analysis of hazards.
And is aimed at the
Pre-emergency activities.
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Emergency time activities.
Post emergency activities.
In the event of an emergency, the people from affected pockets would be directed to move to
safe assemble places nearby the units.
The following facilities will be provided.
Security service
Fire fighting service
Medical service
Pollution control service
Public relation service
Telecommunication service
Transport service
Evacuation service
Welfare service
An alarm system will be provided with a wailing type siren at a centralized place and actuators at
the strategic locations in the plant. Adequate number of telephones will be provided in each unit
at shop floor so that a person can either directly raise the alarm or ring up disaster control room
from where the alarm can be raised directly. The wailing siren will mark the beginning of the
emergency while a continuous note will mark the end meaning all clear signal.
All firefighting equipment like ,valves, fire hydrants, pumps, monitors, etc., will be checked
periodically to detect defective parts and such parts would be immediately replaced. Mock drills
will be conducted for training the persons and to check the performance of men and equipment
and also to keep them fir for any emergency. The plant will be equipped with a separate medical
centre with necessary instrument/appliances, medicines and manpower. The medical officer will
maintain close liaison with different hospital in the nearby city.
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7.10.14 Rescue and Repair Services
The responsibility of effective working of Rescue and Repair service will be with the incident
controller.
Rescue Services
To extricate persons from the debris of collapsed building / structure and safe human
lives.
To hand over the extricated persons to first aid parties.
To take immediate steps as may be necessary for the temporary supports or demolition
of buildings and structures, the collapse of which is likely to endanger life or obstruct
traffic.
To cut off supplies of water, gas, electricity to damaged buildings.
Trained Rescue parties shall be formed at Shop levels, who will be provided with the following
equipment:
Self contained oxygen breathing apparatus
Blower type gas mask
Resuscitators
Petromax lamp/Torches
Axe/hand saw
Bamboo ladder
Necessary Safety appliances
First aid box
Blankets
On-site emergency planning rehearsals will carried out from time to time. It requires monitoring
by experience persons from other similar factories or by senior officials from the State
inspectorate of Factories and /or the
Directorate of Fire Services, who can help in updating the emergency plan procedure.
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7.11 Off-site emergency planning
Off-site emergency planning is normally under the jurisdiction of the district administration. The
designated official of the Steel Plant is required to have co-ordination with the district
administration for responsive action in off-site emergency planning.
7.12 Fire Fighting organization and Procedure
There will be trained fire fighting personnel and a Fire officer under the Fire & safety
department. The following important instructions will be given for fire prevention and tackling of
any fire in the plant.
Overall control of the Fire fighting operations will rest with the senior most officers
present at the scene of fire, who will be assisted by the operational and fire staff. Close
co-ordination and planning for fire protection will be done between plant operations and
fire services.
While turning out for fire calls, the staff will be guided to the correct location
immediately on their arrival.
In-charge of the section at shop floor will explain special risks involved and guide the in
charge of the fire fighting crew. He will, however, not interfere in the method of fire
fighting operations.
No one would tamper with the sources of water supply/fire hydrants or misuse them in
any manner. The passages/approach to /from hydrants to the fire appliance would
always be kept clear.
Fire drills would be held in each, zone periodically under the direction of the Fire Officer.
The organization and brief procedure for fighting small, major and simultaneous fire is given
below:
Degree of fire emergency
Fire chief
Siren code
Persons attending
Small fire Functional head in charge of affected area
No siren First and second line fire-fighting team
Major fire Head of the production Wailings two minutes First, second and third
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department fire fighting teams
Simultaneous fire In-charge of affected area
No siren except for major fire
Persons already present at the scence of fire, operators.
7.13 Definitions:
Small fire: A fire in its incipient stage which is controlled by the first line fire fighting team.
Major fire: The fire is spreading to other equipment or areas and which threatens to go beyond
the control of first line and second line fire fighting teams.
Simultaneous fire: More than one fire occurring at the same time.
Fire Control Office: The Fire Control Officer will be in-charge at the scene of fire. In case of small
fire, Section Head/Functional Head of affected area will be Fire Officer.
In major fire, Head of Production Department will be Fire Control Officer.
In simultaneous fires, in-charge of the respective affected areas will be Fire Control Officers.
Fire call: Fire call will be received at the fire station regarding occurrence of fire and its location.
The message will be conveyed either by telephone or fire alarm or in person.
While giving Fire call message on telephone, the person will
Give his name, Section & Department.
Exact location of Fire and if possible, nature of fire.
Confirm that the fire call message is repeated by the Control room attendant.
When the cal message is Oven by the Fire alarm, the person would stand rear the fire alarm to
guide the fire fighting team to the location of the fire.
7.14 Fire siren code
For small fire No siren will be sounded.
For Major fire Wailing type continuously for two minutes.
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For all clear Straight sound for two signal minutes.
7.15 Testing of the Fire Sirens
Fire sirens may be tested by sounding straight for one minute on every Monday at 9 AM for coke
oven plant and every Wednesday at 9 AM for cogeneration power plant.
7.16 Fire Fighting for small fire
The small fire will be tackled by the first team which would comprise of the persons already
present at the scene of fire. However, the second line fire fighting team whose composition is
given below will also report at the scene of fire immediately after receiving the Fire call of
affected area at the time of fire. The team will consist of the following
7.17 Fire Control Officer
7.17.1 First line Fire Fighting team
Operational / maintenance staff and / or other plant personnel workings in the area.
7.17.2 Second line Fire fighting team
Fire station shift in charge and trained fire fighting personnel.
Ambulance driver with ambulance.
Functional head of affected area.
Shift Officer production.
Security personnel.
7.17.3 Third line Fire fighting team
Fire Officer & Auxiliary Fire Fighting personnel.
All Departmental & Functional Head.
Local Fire Brigade from Government if necessary.
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7.17.4 Responsibilities of Security personnel at the manned gate
To prevent entry unauthorized persons.
To keep the gate open for emergency vehicles and officers and staff concerned with fire
fighting and allied operations.
7.17.5 Responsibilities of Telephone Operator
To receive fire call messages.
To inform Shift Officer for all fires.
7.17.6 Responsibilities of Medical Officer during major fire
To be available at the first aid centre for necessary medical advice.
To depute one of the medical staff to the scene of fire to render any medical assistance,
required at site.
7.17.7 Responsibilities of Head of the Personnel and Welfare Department during major fire
To arrange the transport of the fire fighting personnel with minimum loss of time in
consultation with the Fire Control / Fire Officer.
To make arrangements for the refreshment/meals for persons engaged in fire fighting.
To inform the Fire Officer regarding the actions taken.
7.17.8 Responsibilities of Head of the Maintenance Department during major fire.
To report to Fire Chief and render all help that may be required from Maintenance Department.
7.10.9 Responsibilities of Head of the Electrical Maintenance Department during major fire
To report to Fire Officer and render assistance to be required from Electrical Department such as
installation of equipment, provision of temporary lighting etc.
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7.17.10 Responsibilities of Head of the Materials Procurement Department during major fire
To arrange to man the stores for emergency issue of materials. If the materials are not available
in the stores or are likely to be exhausted during fire fighting operations, he would arrange for
the same from other sources.
7.18 Cloud Burst / Lighting
Cloud burst / lighting may at times lead to minor to major emergency. In such an emergency,
actions indicated under fire and explosion will be undertaken.
7.19 Food Poisoning
In case of food poisoning in plant canteens, the following will be done;
Disaster Controller will inform Medical Officer for immediate first aid.
Medical Officer will contact other hospitals and seek their help, if necessary.
Security will help in evacuating the affected people to various hospitals, in co-ordination
with the Medical Officer.
7.20 Mutual-aid System
At times the possibility of a major emergency (a situation out of control of plant authority )
cannot be ruled out. In such a case, the plant authority would declare it to be a major
emergency and total control would be transferred to the district level officer of contingency plan
committee.
Necessary help would also be sought from Government sources having necessary infrastructure
for dealing with disaster.