table-1.1 table-1

Environmental Impact Assessment for Expansion of Integrated CementProject - Clinker (9.5 MTPA to 13 MTPA), Cement (12 MTPA to 16MTPA), & WHRB (30 MW to 45 MW) near Villages Sangaria, Borakheri,Peerkhera and Rasulpura, Tehsil Nimbahera, District Chittorgarh,Rajasthan

Risk Assessment

VIMTA Labs Limited, Hyderabad R-1

1.0 Risk Assessment

This risk analysis covers the oil fuel storage tanks provided for existing cementplant lines I, II & III and the proposed cement plant line IV, captive power plantand mines of Wonder Cement Limited at Nimbahera, Chittorgarh District,Rajasthan.

FUEL STORAGE TANKS

Details of fuel storage tanks are shown in Table-1.1.

TABLE-1.1DETAILS OF STORAGE TANKS

MaterialStored

Capacity(KL)

Classification

TankDimensions

Type of Tank Location

Dia(m)

Length/

Height(m)

Existing Storage TanksHSD 20 B 2.10 6.25 Under-ground Tank MinesHSD 20 B 2.10 6.25 Under-ground Tank MinesHSD 20 B 2.10 6.25 Under-ground Tank MinesHSD 20 B 2.10 6.25 Under-ground Tank MinesHSD 10 B 2.2 3.30 Above-ground Cone

Roof TankCPP

HSD 10 B 2.2 3.30 Above-ground ConeRoof Tank

Cement Plant Line - I


Cement Plant Line - II


Cement Plant Line - III

Proposed Storage TanksHSD 10 B 2.2 3.30 Above-ground Cone

Roof TankCement Plant Line - IV

Hazard Identification

HSD is a Class B petroleum product with flammable hazard, mainly pool fire.Properties of LDO relevant to this risk analysis study are listed in Table-1.2.

TABLE-1.2HAZARDOUS PROPERTIES OF HSD

Materials NormalBoiling Point

(°C)

Flash Point(min)(°C)

LowerFlammableLimit (%)

UpperFlammableLimit (%)

ProductClass

HSD 215-376 35 0.6 6.0 BConsequence Analysis


Risk Assessment


Damage Effects of Jet/ Pool Fire Radiation

The effect from jet fire and pool fire is thermal radiation intensity on the receptorsurface as shown in Table-1.3.

TABLE-1.3DAMAGE EFFECTS DUE TO JET/ POOL FIRE RADIATION

Heat RadiationIntensity(kW/m2)

Observed Effect

4 Sufficient to cause pain to personnel if unable to reachcover within 20 seconds; 0% lethality.

12.5 Minimum energy required for piloted ignition of wood,melting of plastic tubing.

37.5 Sufficient to cause damage to process equipment.

Thermal radiation intensity exceeding 37.5 kW/m² may cause escalation due todamage of other equipment.

Thermal radiation intensity exceeding 12.5 kW/m² may cause ignition ofcombustibles on buildings and impairment of escape route.

Thermal radiation intensity exceeding 4 kW/m² may cause burn injury onpersonnel injury.

Failure Scenarios for Risk Analysis

The failure scenario cone roof type tanks considered in the risk analysis study ismainly dyke fire caused by ignition of oil spill in the dyke due to leakage oroverflow.

Consequence Analysis Results

Consequence analysis for the identified failure scenarios is carried out using therenowned PHAST software of DNV-GL.

HSD tanks CPP and all the Cement Plant Lines I, II, III & IV are vertical cone rooftanks each with 10 KL capacity.

Results of consequence analysis are summarized in Table-1.4


Risk Assessment


TABLE-1.4SUMMARY OF CONSEQUENCE ANALYSIS RESULTS

Sr.No.

Description ParameterValue

Downwind Distance fromTank Centre (metres)

Weather(Wind speed & Stability)3 m/s; D 5 m/s; D

1. HFO Storage Tank (10 KL) in CPP and Cement Plant Lines I, II, III %IV

Dyke Fire RadiationIntensity

4 kW/m2 22 2212.5 kW/m2 14 1537.5 kW/m2 5 5

In none of the scenarios, vapour cloud explosion hazard is indicated by PHAST software.

The HSD tanks in the Mines area (4 Nos. each 20 KL capacity) are horizontal cylindricaltype installed underground in RCC pits with sand filling. As such, pool fire is not likelyaround these tanks. Graphical results of consequence analysis plotted on plant layoutdiagram are shown in the following Figure-1.1 to Figure-1.2.

FIGURE-1.1LEGEND FOR CONSEQUENCE ANALYSIS GRAPHS


Risk Assessment


FIGURE-1.2HSD TANK IN CPP – DYKE FIRE RADIATION INTENSITY

FIGURE-1.3HSD TANK IN CEMENT PLANT LINE I – DYKE FIRE RADIATION INTENSITY


Risk Assessment


FIGURE-1.4HSD TANK IN CEMENT PLANT LINE II – DYKE FIRE RADIATION INTENSITY

FIGURE-1.5HSD TANK IN CEMENT PLANT LINE III – DYKE FIRE RADIATION INTENSITY


Risk Assessment


FIGURE-1.6HSD TANK IN CEMENT PLANT LINE IV – DYKE FIRE RADIATION INTENSITY

CONCLUSIONS

Based on the results of consequence analysis using Phast software, the followingconclusions emerge.

1. In case of HSD tanks in CPP and Cement Plant Lines I, II, III & IV, the dykefire radiation intensity of 37.5 kW/m2 which can cause damage, does notimpact adjacent equipment or area.

RECOMMENDATIONS

The following recommendations are provided for the purpose of minimizing thepool fire risk due to spillage from oil storage tanks:

1. Each section of the dyke is to be provided with a drain valve, which shall bekept normally closed, and opened only during rains or removal of water.

2. The outlets from dyke drains should be connected to oil water separatorbefore joining the surface drain.

3. The oil storage tanks should be provided with fixed foam pourer as per OISDstandard 244.

4. Portable type medium expansion foam generator is to be provided to handlepool fire effectively as specified in OISD standard 244.


Risk Assessment


5. The flexible hoses used for road tanker unloading should be maintained andchecked regularly to prevent leaks.

6. Road tanker unloading operation should be covered by written standardoperating procedure (SOP). The instructions in local language should bedisplayed on a board at each unloading station.

1.1 Emergency Preparedness Plan

Definition

A major emergency in a work is one, which has the potential to cause seriousinjury or loss of life. It may cause extensive damage to property and seriousdisruption both inside and outside the work. It would normally require theassistance of emergency services to handle it effectively.

Scope

The aim of hazard control and disaster management is concerned with preventingaccidents through good design, operation, maintenance and inspection, by whichit is possible to reduce the risk of an accident, but it is not possible to eliminate it.Since, absolute safety is not achievable; an essential part of major hazard controlmust also include mitigating the effects of a major accident.

An important element of mitigation is emergency planning, i.e. recognizingaccidents as soon as possible, assessing the consequences of such accidents anddeciding on the emergency procedures, both on-site and off-site, that would needto be implemented in the event of an emergency.

Objective

The overall objectives of the emergency plan will be:a) To localize the emergency and, if possible eliminate it; andb) To minimize the effects of the accident on people and property.

Elimination will require prompt action by operations and works emergency staffusing, for example, fire-fighting equipment, water sprays etc. Minimizing theeffects may include rescue, first aid, evacuation, rehabilitation and givinginformation promptly to people living nearby.

To deal with the above emergencies, the Emergency Plan is prepared.

Onsite Emergency Plan

The onsite emergency management of M/s. Wonder Cement Ltd. is given here, asthe same will be applied in case of proposed expansion. Onsite emergency plan ofWCL is given as Annexure-XIV.

Disaster control Management system


Risk Assessment


Disaster Management group plays an important role in combating emergency in asystematic manner. In addition; the implementation of an Emergency ResponsePlan relies on a number of response functions, which deal with different aspectsof emergency, with the most important ones being:

Communication and Co-ordination Fire and Rescue (Emergency Mitigation) Emergency Control Team at Incident

Site Medical Services Security Administration (Logistics and Welfare) Co-ordination with external agencies.

Emergency Control Centre (ECC)

An Emergency Control Centre (ECC) is established from which emergencyoperations are directed and co-ordinated. Centre will be activated as soon as on-site emergency is declared. The ECC will consist of one room, located in an areathat offers minimal risk being directly exposed to possible accidents. During anemergency, the Emergency Management Staff, including the main controller willgather in the ECC. Therefore, the ECC will be equipped with adequatecommunication systems in the form of telephones and other equipment’s to allowunhampered organization and other nearby facility personnel. The ECC will belocated at the following two locations:

Security Office located at Main Gate (marked as “ECC-1” on the plant layoutdrawing)

Alternate ECC at CCR (marked as “ECC-2” in the plant layout drawing). Manning of ECC during Emergency is as follows: Site Main Controller and his alternate Assistant to SMC Telephone Attendant Three Messengers Key Personnel as per the matrix.

The ECC will provide shelter to its occupants against the most common accidents;in addition, the ECC’s communication systems will be protected from possibleshutdown. The ECC will have its own emergency lighting arrangement and electriccommunication systems operation. The ECC will always be ready for operationand provided with the equipment and supplies necessary during the emergencysuch as:

Hazard identification chart, all emergency response plans Population around factory Internal telephone connections and External telephone connections A list of key personnel, with addresses, telephone numbers, etc.


Risk Assessment


Hotline connection to district collector, police control room, fire brigade,Hospital etc.

Public address system (PAS) MSDS of all the materials used in Plant site List of dispensaries and registered medical practitioners around factory Area map of surrounding villages Note pads and ball pens to record message received and instructions The blown up copy of Layout plan showing areas where accident has

occurred Undated copies of the On-site Disaster Management Plan Emergency telephone numbers The names, phone number, and address of external agencies, response

organizations and neighbouring facilities The adequate number of telephone Emergency lights List of fire extinguishers with their type no. and location, capacity, etc Personal protective equipment(PPE) Safety helmets Clock Material safety data sheets for chemicals handled at the facility

Several maps of the facility including drainage system for surrounding areashowing:

Areas where hazardous materials are stored Plant layout Plot plans of storage tanks, routes of pipelines, all water permanent lines

etc. The locations where personal protective equipment are stored The position of pumping stations and other water sources Roads and plant entrances Assembly areas Lay out of Hydrant lines.

Roles and Responsibility

Site Main Controller (SMC):

The Site Main Controller (SMC) has an overall responsibility for directingoperations and calling outside help. The Unit Head assumes the role of SMC. Thealternate would be as per the response level matrix indicated above. Dependingon the location of the emergency site and the prevailing wind direction, the SMCwill decide and use one of the two Emergency Control Centres, the main is at theSecurity Department at Main Gate as ECC-1 and alternate is CCR as ECC-2 forhandling and controlling the emergency. He will then proceed to that EmergencyControl Centre and take overall control of the emergency and provide guidance incritical decision making. Specific Responsibilities / duties of the SMC are asunder:


Risk Assessment


Continually review and assess existing and possible developments todetermine the Most probable course of events and effective methods todeal with them.

Direct a safe shut down and evacuation of plants, if required, inconsultation with the IC and key personnel.

Ensure that casualties are receiving adequate attention. Decide in consultation with Incident Controller and key persons whether an

off-site emergency exists or is likely to take place. If an off-site emergencyexists or it is imminent then arrange to or instruct the concern–

To alert evacuate the public living in the vicinity of the Plant and, if necessary,advise their evacuation.

Call the outside emergency services. Inform district emergency authorities. Co-ordinate with district emergency authorities to mitigate the consequences

outside the factory. Co-ordinate with district emergency authorities for evacuation, shelter,

rescue. Rehabilitation of general public in the vicinity of affected area. Issue authorised statements to the press or the media in consultation with

media contact person. Inform company senior officials. Declare cessation / termination of emergency after having full control on

emergency event. Rehabilitate the affected area after the emergency is over. In case of Strike by the Plant Personnel, identify critical areas of the Plant in

advance. If emergency occurs during the strike, following arrangements arerequired to be made in advance to meet the crisis.

Keep the list of Technical and Administrative Records needed to run thefactory in an emergency and train the team.

Keep the record of Personnel (Non-executive) likely to be available during thestrike and keep the same in safe custody.

Identify alternate arrangements for meeting any emergency in the factory,i.e. by mutual aid with other factories, etc.

Incident Controller (IC)

The Incident Controller (IC) operates from the nearest accident site. For silenthours, i.e. shifts or on holidays the senior most available or shift in-charge,for that shift would work as IC until the arrival of the seniors. Theresponsibilities of the IC are enumerated below:

After getting the emergency call from site, rush to the emergency site toassess the situation and look into the following:

o Check other responders are arrived at site.o Set up communication network with the Emergency Control Centre

(ECC-1 or ECC-2, as the case may be), using Intercom and walkie-talkie.


Risk Assessment


o Take stock of the situation at site and found uncontrollable informSMC. After taking the stock of the situation decide in consultation withSMC for declaring the emergency and inform the security guard at CCRfor sounding the emergency siren.

o Review if plant shutting down is required to contain/ control the hazardand inform SMC and if required shut down the plant in consultationwith SMC. If required evacuate the persons from affected areas bysending them to the assembly points. Guide response teams i.e. fire &rescue and first aid and other personnel to take necessary action.

o Interact with SMC and brief him on possible effects on areas inside andoutside the factory to initiate Off- Site Emergency Response Plan.

o Remain in touch with SMC and inform him about the situation & actionsbeing taken and seek his advice for the critical decisions.

o Ensure that the essential personnel have been called in at siteo Direct all operations within the affected area with following priorities –o Secure safety of personnel, giving priority to saving life and preventing

further injury.o Minimize damage to plant, property and the environment.o Minimize loss of material.o Advice and inform as required by the emergency responders, i.e., Fire

and Security personnel or emergency services.o Preserve evidences, which would be necessary for subsequent

investigation to find out the immediate and underlying causes of theemergency and for concluding preventive measures.

Legal Coordinator

Functional Head (HR) would be the liaison officer. On hearing the emergencysiren or getting the information about emergency he shall immediately cometo Emergency Control Room and provide necessary instructions to his teammembers. The team comprises HOD-HR, HOD-ER, HOD-Security/Admin andMedical Services. His duties are:

o Arrange to send time keepers to the Assembly points for counting thepersons assembled at the assembly points through HOD-ER

o To ensure the casualties receive adequate attention for immediatemedical treatment.

o To arrange additional medical help if so required.o Arrange to inform the relatives of the injured persons after taking

permission from Main Site Controller.o Arrange to keep ready alternative arrangements for transport to carry

out the necessary work related to emergency.o If emergency prolongs arrange relief for the personnel who are

engaged in controlling emergency and organize refreshment or othercanteen facilities.


Risk Assessment


Materials Coordinator

Functional Head (F&C) would be the Materials Coordinator. On hearing theemergency siren or getting the information about emergency he shallimmediately come to Emergency Control Room and provide necessaryinstructions to his team members. The team comprises HOD-Materials, SH-RawMaterials and SH-Stores. His Duties are:

Get the stores opened for requirement of the Fire fighting/safety and othermaterials, which may be required during emergency.

Assess the situation in consultation with SMC and IC for any materialrequirement help at the affected site.

Ensure free movement of trucks of bulk material, if required.

Medical Coordinator

Chief Medical Officer would be the Medical Coordinator. On hearing theemergency siren or getting the information about emergency he shallimmediately perform following duties.

Rush to the hospital on getting information about emergency by siren ortelephone.

Depute one Medical Assistant for spot first aid. Remain in touch with SMC for any help required. If required he shall send the seriously injured persons to the pre-identified

hospitals

Fire & Rescue Coordinator

Section Head (Security & Fire) would be the Fire & Rescue Coordinator. Ongetting message on telephone or by other means about emergency he shallimmediately rush to the affected site with his and work under the command ofIncident Controller.

o The Fire Team members shall immediately start fire-fighting operation byconnecting the hoses to the fire hydrant system or by operating delugesystem.

o The Rescue Team members shall search for any missing person/casualty andcarry out rescue operation and brought to the nearest first aid centre, whereambulance available.

o Ask additional help for cordoning off the area and advise fire personnel forrescue/fire fighting if required

o Arrange to provide water curtains, water monitors, at affected locations ifrequired. Organize and supervise fire-fighting operations if called for.

o Provide necessary respiratory equipments to plant personnel for emergencyuse.

o Advise IC to arrange additional help from nearby by industries, if required.o Give safety precautions to the personnel at rescue work.Safety Coordinator


Risk Assessment


HOD (Safety) would be the Safety Coordinator. On hearing the emergency sirenor getting the information about emergency he shall immediately come toEmergency Control Room and provide necessary instructions to his teammembers and advise them to report at emergency site. His duties are:

His main role is to advise SMC on Occupational Health and Safety matters. Make arrangements for all necessary safety equipment, breathing apparatus,

fire entry suit, etc.

Security Coordinator

HOD (Security/Admin) would be the Security Coordinator. On getting message ontelephone or by other means about emergency they shall immediately rush to themain security gate and arrange as follows:

Advise the security person at security department to activate the barrackalarm to call additional security personnel at colony

Arrange to send the Security Guards/Firemen to the affected site for providingthe help to Emergency teams.

Arrange to close all the Security gates except Main Gate for any kind ofunauthorized entry in the plant.

Arrange for all necessary fire fighting, foam making and rescue equipments. Guide the Outside helping agencies such as Fire Brigade, ambulances, etc to

the emergency site. Arrange for traffic and mob control. Arrange to take the transporter trucks/vehicles outside the main gate.

Engineering Activities Controller

The person form the section /department from where emergency situation raised,is lead as the controller. He would be assisted by maintenance and electricalpeople. On hearing the emergency siren or getting information of the emergencyhe shall arrange to send the Electrician and Mech. Fitter to the Pump House toensure the pumps are operating with uninterrupted electrical supply and withoutany problem.

To arrange electrical shut down of the affected plant or portion thereof aftergetting information by the Main Site Controller/Incident Controller.

Make arrangements for necessary tools, forklift, etc for carrying out salvageoperation to save the unaffected material from the affected site.

Make arrangements for emergency illumination/ lighting in case of powerfailure during night time.

Other functions

Transport In-chargeOn hearing the emergency siren or getting the information about emergency heshall immediately rush to the Emergency Control Room for providing vehicles foremergency duties and shifting casualties to Medical Centre.


Risk Assessment


Communication Coordinator

Shift Security Supervisor at CCR would work as communication coordinator. Ongetting the information about the onsite emergency from on duty process ShiftEngineer of affected area only, he shall perform following duties.

Send one security to ECC to operate. Inform immediately all the key personnel about the Incident individually on

telephones.

ETP Officer

Arrange all available resources for efficient housekeeping and cleanliness workof affected site after the emergency is over.

Make necessary arrangement for treatment of effluent/fire water/fire fightingfoam/chemical spillage satisfactory at the Effluent Treatment Plant to avoidthe pollution control problem.

Person who notices the Emergency

The initial response by individual to an emergency situation will make thedifference, as seconds count. The people in the departments are trained for usingof the fire extinguishers. If anybody notices the fire or any other emergency theyshould act as follows:

Inform immediately about the fire to the concerned process control room andto the Security Department (dial 339). Also make the announcement aboutthe fire on PA system, if available.

Try to extinguish the fire with the help of fire extinguisher/ fire hydrantsystem/ CO2 total flooding valve/deluge valve. Take the help from others ifrequired.

If the fire is extinguished at its initial stage inform Safety Department andSecurity Department.

Emergency Communication

The views of the possible hazards that can arise out of the daily operations in theplant various measures are adopted to prevent the occurrence of a majoraccident. This comprises of:

a) Built in safety measures, alarms, trips and interlocks etc.b) Standard safe operating and maintenance procedures permit system etc.c) Training of all the involved staff in normal and emergency operatingprocedures.d) Training of all employees in safety, fire fighting and first aid.

However, in spite of these precautions, it is required to foresee situation of majoraccident and plan for taking timely action to minimize the effects of such incident


Risk Assessment


on the safety and health of persons working in the plant as well as those situatedaround the premises. Hence the present plant is drawn up to serve as the manualof handling major emergencies.

Internal telephone systems are provided at work places. Shift In charge at siteand other In charge also given on call handset (Walkie Talkie) for immediatecommunication to all concerned. The shift in charge /Site in charge willimmediately inform department Head / in-charge, security and dispensary (ifrequired). The department head in charge will inform Vice president and factorymanager who according to severity of emergency will inform about theemergency to Senior President.

In case of devastating fire / major accident or hazard, immediate information willbe given as per need to following through telephone operators who will beavailable round the clock over phone.

On-site emergency planning for cement plantFollowing onsite measures will be taken to avoid/ minimize the risk of accidents &other hazards in cement plant and power plant:

(i) Alarm and Communication Systems

Communication is crucial factor in handling an emergency. It is the practiceat many plants that any employee can raise an emergency alarm, so allowingthe earliest possible action to be taken to control the situation.

Alarm systems vary and will depend on the size of the plant. There should bean adequate number of points from an audible warning, or indirectly, viz. asignal or message to a permanently manned location. The alarm should alertthe people to implement appropriate emergency procedures. In areas wherea high level of noise; it may be necessary to install more than one audiblealarm transmitter or flashing lights. Automatic alarms may be appropriate onsome sites.

There should be a reliable system for informing the emergency services assoon as the alarm is raised on site. The details of the communicationarrangements should be agreed locally; in some cases it may be advisable tohave a direct line to the fire bridge. Predetermined code works to indicate thescale and type of the emergency may be valuable.

(ii) Fire-fighting System

In view of vulnerability to fire, effective measures will be taken to minimizefire hazard. Fire protection is envisaged through hydrant and sprinklersystem, designed as per the recommendation of Tariff Advisory Committee ofInsurance Association of India. The following areas in the power station aremainly susceptible to fire:


Risk Assessment


Cable galleries Electrical switchgear/ MCC room Coal handling areas: Conveyors, transfer points, tunnels and storage yard. Transformers and turbine oil tank

For containment of fire and preventing it from spreading in cable galleries,section wise fire barriers with self - closing fire resistant doors will beprovided. The ventilation systems, if any, provided in cable galleries will beinterlocked with the fire alarm system, so that in event of a fire, theventilation system will be automatically switched off. In order to avoidspreading of fire all cable entries opening in cable galleries, tunnels, channels,floors, barriers etc will be sealed with non-inflammable/Fire resistant sealingmaterials.

For detection and protection of the plant against fire hazard, any one or acombination of the following systems will protect susceptible areas:

Hydrant system. Automatic high velocity spray system Medium velocity spray system Portable fire extinguishers Fire alarm systems

Fire hydrant points will be provided throughout the premises. Automatic highvelocity spray system will be provided for protection of transformers and cablegalleries. Manual medium velocity spray system will be provided for protectionof fuel oil and turbine oil storage tanks and coal conveyor galleries.

Water for hydrant, spray and sprinkler system will be supplied from thefirewater pumps located in firewater pump house adjacent to Raw WaterReservoir. Adequate number of portable and mobile chemical fireextinguishers will be provided at strategic locations throughout the plant. Firedetection and alarm system will be provided at strategic locations throughoutthe plant. Fire detection and alarm system will be provided to detect fire/smoke in vulnerable areas of the plant through smoke /heat detectors.Table-1.5 & Table-1.6 enlists case & Site specific Fire extinguishersrespectively.

TABLE-1.5LIST OF EXTINGUISHER TO BE USED AS CASE SPECIFIC

Sr.No.

Chemical Name Type of Extinguisher

1. Coke Use: Water fog, CO2, Foam, Dry Chemical2. Fuel Oil Use: Water spray, foam, dry powder or carbon dioxide

Do Not Use: water jet as an extinguisher, as this willspread the fire


Risk Assessment


3. HSD Use: Foam, Carbon dioxide, Dry Chemical Powder.Water may be used to cool fire-exposed containers

4. LDO Use: water fog, foam, dry chemical or carbon dioxide(CO2) to extinguish flames

5. Fly Ash Non Flammable6. Gypsum Non Flammable7. Laterite Non Flammable8. Metal dust Certified class D Extinguishing agent

TABLE-1.6LIST OF EXTINGUISHER TO BE USED AS SITE SPECIFIC

Sr.No.

Name of site Type of Extinguisher

1. Cable galleries CO2 & Foam type, Dry chemical powder2. High voltage panel CO2 & Foam type, Dry chemical powder3. Control rooms CO2 & Foam type, Dry chemical powder4. MCC rooms CO2 & Foam type, Dry chemical powder5. Pump Houses CO2 & Foam type, Dry chemical powder6. Guest houses and offices Dry chemical powder, foam type7. Godowns Foam type8. Bunkers, Silo, enclosed

dust collectorCO2 type, N2 type, automatic sprinkler,fixed spray nozzle (unless water reactive)

(iii) Evacuation Procedure

As the major hazard is only due to fire, which has more or less localizedimpact no mass evacuation, procedures are required. Evacuation wouldinvolve only the people working very close to the fire area.

(iv) First Aid

A first aid center with adequate facilities shall be provided. It shall bemaintained round the clock by a compounder cum dresser and a doctor.An auxiliary first aid squad shall be identified, the members of which shallbe spread in each shift in different departments. In the event of anemergency this squad will augment medical services. An Ambulance whichis available with plant shall also be used at site to carry affected people tohospital. Assistance of these hospitals will be taken in case of anynecessity.

(v) Safety

The safety wing led by a Safety officer will meet the requirement ofemergencies round the clock. The required safety appliances shall be


Risk Assessment


distributed at different locations of the plant to meet any eventualities.Poster/placards reflecting safety awareness will be placed at differentlocations in the plant area.

(vi) Emergency Drills

The emergency response plans and emergency preparedness level wouldbe tested through the following drills:a. Table-top exercise (TTE)b. Functional exercise (FE)c. Full-scale exercise (FSE)

All elements/procedures of the On-Site Emergency Plan would be firsttested through TTE and perfected to the extent possible. The Plan thenwould be modified/ updated. Functional Exercises basically to ensureproper functioning of various equipment such as the fire-fightingequipment and the fire hydrant system. The Full-Scale Drill would beconducted to know the level of preparedness of all teams. Initially, TTEand FE would be conducted periodically.

The following drills are conducted periodically:

a) Plant Emergency Drill for fireb) Fire Drills at offices and admin buildingc) Plant Emergency Drills (fire scenario involving evacuation)

(vii) Personal Protective Equipments (PPEs)

Personal protective equipments play a vital role in overcoming majordisastrous situation saving life during onsite emergency. List ofrecommended Personal Protective equipment (PPE) is given below inTable-1.7.

TABLE-1.7SUMMARY OF RECOMMENDED PERSONAL PROTECTIVE EQUIPMENT

ACCORDING TO HAZARD ONSITE

Objective Workplace Hazards Suggested PPEEye and faceprotection

Flying particles, moltenmetal, liquid chemicals,gases or vapors, lightradiation

Safety glasses with side-shields,protective shades, etc.

Head protection Falling objects, inadequateheight clearance, andoverhead power cords

Plastic helmets with top and sideimpact protection

Hearingprotection

Noise, ultra-sound Hearing protectors (ear plugs or earmuffs)

Foot protection Failing or rolling objects, Safety shoes and boots for protection


Risk Assessment


Objective Workplace Hazards Suggested PPEpoints objects. Corrosive orhot liquids

against moving and failing objects,liquids and chemicals

Hand protection Hazardous materials, cuts orlacerations, vibrations,extreme temperatures

Gloves made of rubber or syntheticmaterial (Neoprene), leather, steel,insulation materials, etc.

Respiratoryprotection

Dust, fogs, fumes, mists,gases, smokes, vapors

Facemasks with appropriate filters fordust removal and air purification(chemical, mists, vapors and gases).Single or multi-gas personal monitors,if available

Oxygen deficiency Portable or supplied air (fixed lines).Onsite rescue equipment

Body / legprotection

Extreme temperatures,hazardous materials,biological agents, cutting andlaceration

Insulating clothing, body suits, apronsetc. of appropriate materials

Fly Ash Fly ash handling and storage Wear dust-proof goggles and rubberor PVC gloves.When using large quantities or whereheavy contamination is likely, wear:coveralls.At high dust levels, wear: a Full-faceClass P3 (Particulate) or an Air-linerespirator where an inhalation riskexists, wear: a Class P1 (Particulate)respirator.

Apart from this, all the employees are provided with helmets and safety shoes. Itis statutory on the part of the company employees to wear the appropriate safetygear given while attending duty in the factory.

Off-Site Emergency Planning

The off-site emergency plan is an integral part of any hazard control system. It isbased on those accidents identified by the works management, which could affectpeople and the environment outside the works. Thus, the off-site plan followslogically from the analysis that took place to provide the basis for the on-site planand the two plans therefore complement each other. The roles of the variousparties that may be involved in the implementation of an off-site plan aredescribed below.

The responsibility for the off-site plan will be likely to rest either with the worksmanagement or with the local authority.


Risk Assessment


Either way, the plan must identify an emergency coordinating officer who wouldtake overall command of the off-site activities. Consideration of evacuation mayinclude the following factors:

In the case of a major fire but without explosion risk (e.g. an oil storagetank), only houses close to the fire are likely to need evacuation

If fire is escalating very fast it is necessary to evacuate people nearby assoon as possible.

In acute emergency people are advised to stay indoors and shieldthemselves from the fire.

Organization

Organizational details of command structure, warning systems, implementationprocedures, emergency control centres include name and appointments ofincident controller, site main controller, their deputies and other key personnelinvolved during emergency.

Communications

Identification of personnel involved, communication centre, call signs, network,list of telephone numbers.

Special Emergency Equipment

Details of availability and location of heavy lifting gear, specified fire-fightingequipment, fireboats etc.

Voluntary Organizations

Details of Voluntary organizations, telephone numbers nearby of hospitals,Emergency helpline, resources etc are to be available with chief authorities.

Non-government Organizations (NGO)

NGO’s could provide a valuable source of expertise and information to supportemergency response efforts. Members of NGOs could assist response personnelby performing specified tasks, as planned during the emergency planningprocess.

Evacuation of personnel from the affected area Arrangements at rallying posts and parking yards Rehabilitation of evacuated persons.

Chemical information

Details of the hazardous substances (MSDS information) and a summary of therisks associated with them are to be made available at respective site.


Risk Assessment


Meteorological information

There is to be arrangements for obtaining details of weather conditions prevailingat before the time of accident and weather forecasts updates.

Humanitarian Arrangements

Transport, evacuation centres, emergency feeding, treatment of injured, first aid,ambulances, temporary mortuaries.

Public Information

Dealing with the media-press office Informing relatives, etc.

Assessment

Collecting information on the causes of the emergency Reviewing the efficiency and effectiveness of all aspects of the emergency

plan.

Role of local authority

Local Authorities like Panchayat, Sabha, Samity, municipalities can help incombating emergency situation after assessing the impact scenario in rescuephase.

Role of police

The police is to assist in controlling of the accident site, organizing evacuation andremoving of any seriously injured people to hospitals.

Co-ordination with the transport authorities, civil defence and homeguards

Co-ordination with army, navy, air force and state fire services Arrange for post mortem of dead bodies Establish communication centre with easy contact with ECC.

Role of Fire Brigade

The fire brigade is to be organized to put out fires and provide assistance asrequired during emergency.

Media

The media is to have ready and continuous access to designated officialswith relevant information, as well as to other sources in order to provideessential and accurate information to public throughout the emergencyand to avoid commotion and confusion.


Risk Assessment


Efforts are made to check the clarity and reliability of information as itbecomes available, and before it is communicated to public.

Public health authorities are consulted when issuing statements to themedia concerning health aspects of chemical accidents.

Members of the media are to facilitate response efforts by providingmeans for informing the public with credible information about accidentsinvolving hazardous substances.

Role of health care authorities

Hospitals and doctors must be ready to treat all type of injuries tocausalities during emergency.

Co-ordinate the activities of Primary Health Centres and MunicipalDispensaries to ensure required quantities of drugs and equipments.

Securing assistance of medical and paramedical personnel from nearbyhospitals/institutions.

Temporary mortuary and identification of dead bodies.

Conclusion

It has concluded that there will be no major risk involved due to proposed projectactivity. Proper precaution will be taken so risk can be minimized. PersonalProtective Equipment’s (PPEs) will help to minimize the health hazards andaccidental casualties. So it is safe to say that there will be no major risk involveddue to the proposed project activity.

1.2 Occupational Health and Safety

Large industries, in general where multifarious activities are involved duringconstruction, erection, testing, commissioning, operation and maintenance, themen, materials and machines are the basic inputs. Along with the boons, theindustrialization generally brings several problems like occupational health andsafety.

The industrial planner, therefore, has to properly plan and take the steps tominimize the impacts of industrialization and to ensure appropriate occupationalhealth, safety including fire plans. All these activities again may be classified underconstruction and erection, and operation and maintenance. The proposed safetyplan is given below.

1.2.1 Occupational Health

Occupational health needs attention both during construction and erection andoperation and maintenance phases. However, the problem varies both in magnitudeand variety in the above phases.

Construction and Erection


Risk Assessment


The occupational health problems envisaged at this stage can mainly be due toconstructional accident and noise. To overcome these hazards, in addition toarrangements to reduce it within TLV's, personal protective equipment shall also besupplied to workers.

Operation and Maintenance

The problem of occupational health, in the operation and maintenance phase is dueto noise hearing losses. Suitable personnel protective equipment shall be given toemployees. The working personnel shall be given the following appropriatepersonnel protective equipment.

Industrial Safety Helmet Crash Helmets Face shield with replacement acrylic vision Zero power plain goggles with cut type filters on both ends Zero power goggles with cut type filters on both sides and blue color glasses Welders equipment for eye and face protection Cylindrical type earplug Ear muffs Canister Gas mask Self contained breathing apparatus Leather apron Aluminized fiber glass fix proximity suit with hood and gloves Boiler suit Safety belt/line man's safety belt Leather hand gloves Heat resistant hand gloves Acid/Alkali proof rubberized hand gloves Canvas cum leather hand gloves with leather palm Electrically tested electrical resistance hand gloves Industrial safety shoes with steel toe Electrical safety shoes without steel toe and gum boots

Full fledge hospital facilities are made available round the clock for attendingemergency arising out of accidents, if any. All working personnel shall bemedically examined at least once in every year and at the end of his term ofemployment.

1.2.2 Safety Plan

Safety of both men and materials during construction and operation phases is ofconcern. The preparedness of an industry for the occurrence of possible disasters isknown as emergency plan. The disaster in plant is possible due to leakage of fuels,collapse of structures and fire/explosion etc.

Keeping in view the safety requirement during construction, operation andmaintenance phases, the following regulations shall be considered:


Risk Assessment


To allocate sufficient resources to maintain safe and healthy conditions ofworking environment;

To take steps to ensure that all known safety factors are taken into account inthe design, construction, operation and maintenance of plants, machinery andequipment;

To ensure that adequate safety instructions are given to all employees; To provide wherever necessary protective equipment, safety appliances and

clothing and to ensure their proper use; To inform employees about materials, equipment or processes used in their

work, which are known to be potentially hazardous to health or safety; To keep all operations and methods of work under regular review for making

necessary changes from the point of view of safety in the light of experience andupto date knowledge.

To provide appropriate facilities for first aid and prompt treatment of injuries andillness at work.

To provide appropriate instruction, training, retraining and supervision toemployees in health and safety, first aid and to ensure that adequate publicity isgiven to these matters.

To ensure proper implementation of fire prevention methods and an appropriatefire fighting service together with training facilities for personnel involved in thisservice.

To organize collection, analysis and presentation of data on accident, sicknessand incident involving personal injury or injury to health with a view to takingcorrective, remedial and preventive action.

To promote through the established machinery, joint consultation in health andsafety matters to ensure effective participation by all employees.

To publish/notify regulations, instructions and notices in the common languageof employees.

To prepare separate safety rules for each type of occupation/processes involvedin a project.

To ensure regular safety inspection by a competent person at suitable intervalsof all buildings, equipment, work places and operations.

1.2.3 Safety Organization

Construction and Erection Phase

A qualified and experienced safety officer shall be appointed. The responsibilitiesof the safety officers include identification of the hazardous conditions and unsafeacts of workers and advise on corrective actions, conduct safety audit, organizetraining programs and provide professional expert advice on various issuesrelated to occupational safety and health. He is also responsible to ensurecompliance of Safety Rules/ Statutory Provisions. In addition to employment ofsafety officer by power plant, every contractor, who employs more than 250workers, shall also employ one safety officer to ensure safety of the worker, inaccordance with the conditions of contract.

Operation and Maintenance Phase


Risk Assessment


When the construction is completed the posting of safety officers shall be inaccordance with the requirement of Factories Act and their duties andresponsibilities shall be as defined thereof.

1.2.4 Safety Circle

In order to fully develop the capabilities of the employees in identification ofhazardous processes and improving safety and health, safety circles would beconstituted in each area of work. The circle would consist of 5-6 employees fromthat area. The circle normally shall meet for about an hour every week.

1.2.5 Safety Training

A full-fledged training center shall be conducted at the plant. Safety training shall beprovided by the Safety Officers with the assistance of faculty members called fromCorporate Center, Professional Safety Institutions and Universities. In addition toregular employees, limited contractor labors shall also be provided safety training.To create safety awareness safety films shall be shown to workers and leaflets etc.Some precautions and remedial measures proposed to be adopted to prevent firesare:

Compartmentation of cable galleries, use of proper sealing techniques of cablepassages and crevices in all directions would help in localizing and identifying thearea of occurrence of fire as well as ensure effective automatic and manual firefighting operations;

Spread of fire in horizontal direction would be checked by providing fire stops forcable shafts;

Reliable and dependable type of fire detection system with proper zoning andinterlocks for alarms are effective protection methods for conveyor galleries.

Housekeeping of high standard helps in eliminating the causes of fire andregular fire watching system strengthens fire prevention and fire fighting; and

Proper fire watching by all concerned would be ensured.

1.2.6 Health and Safety Monitoring Plan

All the potential occupational hazardous work places such as fuel storage area,coal/Pet-coke handling area shall be monitored regularly. The health of employeesworking in these areas shall be monitored once in a year for early detection of anyailment.

Though effective measures are taken to combat pollution in ambient conditions,occupational health hazards are not overlooked. Project will provide well organizedoccupational health services to all its employees by taking responsibility forestablishment and maintenance of safe and healthy working environment andassessment of the physical and mental capabilities to turn out specific workloads.


Risk Assessment


The industrial medical centre will have following responsibilities:

1. Surveillance of workers health in relation to work;2. Surveillance of working environments;3. Identification and evaluation of environmental factors which may affect the

workers health;4. Assessment of conditions of occupational workers health; and5. Observance of safety norms and reduce/eliminate exposure to hazardous

environs.

WCL will take up monitoring activities periodically to assess hazards due to gases,dusts, vibrations, radiations etc.

Occupational health reports of the workers for the years 2017 and 2018 is given inAnnexure-XV.

1.3 Social Impact Assessment Study

This draft SIA report has been prepared as part of the draft EIA for conductingPublic Hearing at the project location. The final SIA report along with thecommunity concerns expressed during public hearing will be incorporated in SIAreport and submitted to MoEF&CC for obtaining Environmental Clearance.The major objective of the study is to understand the socio-economic situation ofthe respondents within the project study area and making a need basedassessment. Further, the concentration of the study is based on following specificobjectives such as:

1. To study the socio-demographic and economic background of the study areapopulation;

2. To understand the educational and health status of the respondents;3. To study the conditions of employability and livelihood of the respondents;4. To make an attempt to understand the resource assessment of the

household of the respondents;5. To assess the needs and priorities of the population, resided in the study

area;6. To reveal the information about the existing CSR activities from the

respondents; and7. To suggest remedies and measures for inclusion of all the stakeholders in

the developmental spectrum of the setting.

Section 135 of the Companies Act, 2013 (“Act”) provides that a company havingnet worth of rupees five hundred crores of more or turnover of rupees onethousand crores or more or a net profit of rupees five crores or more mustconstitute a corporate social responsibility committee (“CSR Committee”)consisting of three or more directors, one out of whom must be an independentdirector. The CSR Rules have been notified on 27th February 2014 and it cameinto force from 1st April 2014. The WCL CSR Committee has been formulated asper corporate social responsibility policy (“CSR Policy”).


Risk Assessment


In addition to the CSR initiatives implemented as per the Companies Act 2013,M/s Wonder Cement Limited-WCL is also committed to follow the MoEF & CC’sguidelines to take up Corporate Environment Responsibility-CER during theproject phase and support in project affected area. In this regard M/s WCL isplanned the Corporate Environment Responsibility-CER budget for next five yearsstarting from 2019 to 2023 which is an additional to the CSR budget. Theproposed budget under CER is 3.75 Crores in next five years (for brownfieldprojects 0.25% on total project cost 1500 Crores as per Officer Memorandum #F.No. 22-65/2017-IA.III dated 1st May 2018 of MoEF&CC Impact AssessmentDivision).

Detailed report of the SIA study is given as Annexure-XVI.

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