CHAPTER 8 DISASTER CONTROL PLAN

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1 CHAPTER 8 DISASTER CONTROL PLAN 8.0 DISASTER OR EMERGENCY CONTROL PLAN KSPL management has planned policy in environmental protection, ensuring safety and health of all employees as well as well being of the people in the surrounding areas. It is likely that any activity of the plant can create threat / danger / hazard due to storage of alcohol. Proposed captive power generation plant also can cause fire, electrocution and explosion hazards. Karan Sugar Pvt. Ltd. is already covered under Factories Act 1948 & Maharashtra Factories Rules 1963 with all amendments till today and all directives from Director Safety, Health & Environment [SHE] are binding on KSPL. KSPL management is bound to appoint a qualified Safety Officer. On site and off site disaster control plans, their perfect implementation will be part and parcel of the project & duty of safety officer. To lessen the probability of hazard to materialize & avoid the consequent damage, a disaster management and control plan has been worked out for whole complex Type of Disaster at KSPL complex Disaster can occur at site or off site i.e. disaster on campus or disaster in nearby area causing indirect damage to site area and the complex. Disaster is classified into two categories such as, Natural and Manmade calamities: Natural calamities :- Flood, Storm / typhoon, Earthquake, Tsunami, Heavy mist, fog, hail storm, eruption of volcano, Land slide Man made calamities involve:- Fire & Explosion, All types of leakages & spillage, Electrocution, Accidents during excavation, construction activities, erection, or sabotage, rail & road accidents, mass agitation, looting, morcha, mass agitation, war etc. The identified Dangerous areas in the complex are:- 1. Boiler area - Explosion 2. Oil tanks - Fire and spillage 3. Turbine section - Explosion

2 4. Electrical rooms - Fire and electrocution 5. Transformer area - Fire and electrocution 6. Cable - Fire and electrocution 7. Storage facilities Fire / spillage for fuel and alcohol Considering various probabilities the management & safety department will create safety awareness & preparedness in all employees and people in vicinity area in case of any emergency & a chalk out plan to overcome the disaster in time. This includes preparation of onsite and offsite disaster control plans, impart training to staff and employees, conducting regular mock drills at least 2 times in a calendar year, reports schemes to DISH & take their guidance for the perfect implementation Level of Accident If there is any disaster in any part of plant/work place due to any reason the level of accidents from damage point of view may vary. Accordingly accident prevention program will have to be initiated by safety department simultaneously Critical targets during emergency Level I Accidents Under this level disaster may happen due to electrocution, fire explosion, oil spillage and spontaneous ignition of combustible material. This level has probability of occurrence affecting persons inside the plant. Level II Accidents In second level cases of sabotage and compete failure of all automatic control/warning systems, and also if the start up fuel oil stored in tank and covered by tank bunds leaks out. However, probability of occurrence of Level II Accidents reduces due to the proposed adequate security training, and education level of plant personnel for the captive power plant Site emergency control room (SECR) & site main controller In each segment of work from domestic level to war fighting team level approach always helps. If concerned man is aware of his duty at his place & need of the time he can complement to huge task of containing the damage of the disaster. To overcome the emergency in its occurrence it is the strategy to get prepared in advance, plan for the team effort, educate others and reduce all effects of disaster.

3 In case of any disaster main responsibility lies with the Chairman and Board of Directors, where they nominate one person as responsible who will be Chief incidence controller. In case of disaster key person like Chief engineer, Chief chemist, Distillery manager, Safety officer will be appointed as the site main incidence controller and will commence respective duties in that capacity to curtail the emergency & minimize the losses may be occurring. People in all departments can render assistance in form of contacting external persons or agencies, district, state and central authorities, hospital & ambulance contact, police department for evacuation if needed for people in the vicinity with assistance of state transport buses. People from maintenance department are to rectify the fault in system as early as possible. Security persons have to assist in fire fighting & segregation of material to avoid losses. All situations should be visualized and plan safety operations involving all staff in factory to get any sort of external help / assistance in time to lessen all sorts of damage. To ensure disaster is controlled effectively a site emergency control room (SECR) will be established at the plant site. The SECR shall keep following information and accessories ready and prominently displayed and start to act as detailed if the emergency occurs: List of telephone numbers of Chairman & Directors KSPL, Chief Engineer, Chief Chemist, Distillery Manager, Administration Manager. Telephone numbers of Sarpanch and members of Panchayat of Harwad village, members of city council of Shirol town, Collector, Kolhapur district, Shirol regional State road transport depot office, Kolhapur District & local fire brigade station, home guard, civil defense, N.C.C. unit, State crisis group, Shirol, crisis group. All material handling & incoming vehicle traffic to be stopped or diverted All out going lines to be used to contact above authorities. Captive power plant layout with details of inventories and locations of fuel storage areas Oil / furnace oil storage tanks, bagasse, rice husk, coal storage yard etc. Hazard identification chart, maximum number of people working at a time, assembly points etc List of village and their population in the vicinity of proposed plant

4 Public address system like loud speaker, battery operated speaker, sirens, Whistles, batteries, signaling flags etc. Rechargeable and battery operated torch lights and invertors. Tie up with nearest hospital for medical assistance and facility for stretchers, chairs etc. List of registered medical practitioners in vicinity. Study map showing various villages and towns in the vicinity of plant. Muster Roll of all present employees. Note pads and ball pens to record message received and instructions to be passed to concerned persons The blow up copy of Layout plan showing areas where accident could occur. Accident mock drill for at least 2 times in a calendar year is to be a part of Routine exercise. The report before such drill has to be submitted to DISH for information and approval Disaster preventive measures The proposed plant will have following preventive measures to avoid occurrence of disasters: I. Specification & marking of safe area to gather in emergency. II. Design, manufacture and construction of plant, machineries and buildings will be as per national and international codes as applicable in specific cases and laid down by statutory authorities. III. Provision of adequate access ways for movement of equipment and personnel. IV. Minimum two numbers of gates to escape during disaster shall be provided. V. Fuel oil storage shall be in protected and fenced. The tank will be housed in a dyke wall. As per regulations of Chief Controller of Explosives, it s testing & certification will be performed each 5 years regularly.

5 VI. Proper color coding for all process water, air & steam lines will be done. VII. Proper insulation for all steam & condensate, hot water lines will be done. VIII. Provision of circuit brakers, isolation switches, signals will be provided as per electricity act & rules. IX. Proper & rigid bonding and earthing to all equipment will be arranged. X. Meger value of earthing connections will be checked each 6 months and the same record will be available. XI. System of fire hydrants comprising, of electrical motor driven fire pumps is planned. The fire hydrant system will have electrical motor and a generator driven jockey pump to keep the fire hydrant system properly pressurized. XII. Automatic water sprinkling system is planned for all transformers FIRE FIGHTING SYSTEM AS PER (TAC) NORMS: The fire detection and protection system has been planned to meet the above objective according to Tariff Advisory Committee (TAC) of India. The complete fire protection system will comprise of the following (a) Sprinkler system Automatic with manual switchover sprinkler system will be installed for fire detection & alarm system followed by initiation of water spays in area with likelihood of fire hazards. (b) Fire Hydrant Fire hydrants are provided at all around in the plant at specific distance as per TAC Norms. (c) Portable fire extinguishers Various areas of the plant have one or more of the above system depending upon the particular nature of risk involved in that area. (d) Portable Chemical Fire Extinguishers These are intended as a first line of defense, and hence are stationed at strategic locations in different buildings and also for outdoor facilities. Portable fire extinguishers are foam type; carbon dioxide type and multipurpose dry chemical (MPDC) type.

6 (e) Fire Detection and Alarm System This system comprises fire alarm panels, automatic fire detectors, manual call points and fire siren (hooter). The main fire alarm panel provides both visual and audible alarm of fire in any protected areas of the plant. Manual break glass type fire alarms are provided at strategic locations where high hazards exits. Automatic fire detectors are provided for coal handling areas and in plant areas such as control rooms, switchgear rooms, cable galleries etc. First Aid A first aid centre with adequate facilities is provided. An Ambulance is provided at site to carry affected people to hospital. Security The security requirements of the company premises are taken care by CSO assisted by a Fire In charge. Safety - The required safety appliances are distributed at different locations of the plant to meet any eventualities. Evacuation Procedure As the major hazard is due to fire, which has more or less localized impact no mass evacuation, procedures are required. Evacuation would involve only of the people working very close to the fire area. Emergency Control Center Provision is made to establish an Emergency Control Centre (ECC) from which emergency operations are directed and coordinated. The ECC consists of one room, located in an area that offers minimal risk being directly exposed to possible accidents.

7 The ECC is always ready for operation and provided with the equipment and supplies necessary during the emergency such as: Updated copies of the On site Disaster Management Plan. Emergency telephone numbers. The names, phone number, and address of external agencies, response Organizations and neighboring facilities. The adequate number of telephone (more than two). Emergency lights. List of fire extinguishers with their type no. and location, capacity, etc. Personal protective equipment. Safety helmets List of quantity & location. Clock. Status boards/message board. Material safety data sheets for chemicals handled at the facility. Fire is one of the main causes to initiate an emergency situation. It always pays in time if due attention is given to all materials and combustibles present on site and their quantities in time. It can occur any time and hence one aught to be vigilant and cautious nature of management and all staff always helps to lessen the cases of fire accidents. To meet any sort of challenges in case of fires, BIS 2190 provides Indian standards for firefighting equipment. All firefighting equipment and extinguishers have to be planned according to this standard as explained in the table below.

8 There are 4 classes of fire extinguishers: Class Materials Extinguisher A Cotton, Cloth, paper, wood Water type B Oils, Hydrocarbons, Alcohol, Greases CO 2 type C Gases, CNG, LPG, Acetylene, Foam type D Electrical & metals Foam Recommendation The fire tender, which will be part of project with following minimum fire fighting arrangements, shall be procured: Water tank liters CO liters Foam tank - 45 liters CO 2 type fire extinguishers - 6 nos. of 4.5 kg each 8.7. Location type of fire extinguishers Turbo-generator area CO 2 Type, Foam Type Dry chemical powder. Cable galleries CO 2 Type, Foam Type Dry chemical powder High voltage panel CO 2 Type, Foam Type Dry chemical powder. Control rooms CO 2 Type, Foam Type Dry chemical powder. MCC rooms CO 2 Type, Foam Type Dry chemical powder. Pump houses CO 2 Type, Foam type dry chemical powder. Fuel tank Area CO 2 type, Foam Type Dry chemical powder Sand Basket.

9 Offices & Godowns Foam or Dry chemical powder Type. Crushers house CO 2 Type, Foam Type dry chemical powder. Alcohol storage tank area, foam type dry chemical powder and sand basket Alarm system to be followed during disaster On the receiving of message of Disaster from Site Main Controller, fire station control room attendant will crash Siren WAVING TYPE for 5 minutes. Incident controller will arrange to broad cast disaster message through public address system. On receiving the message of Emergency Over from incident Controller the fire station control room attendant will give All Clear Signal by sounding alarm straight for two minutes. The features of alarm system will be explained to one and all to avoid panic or misunderstanding during disaster. It is necessary to take one trial for perfect functioning of the siren at least once in one week with prior intimation to Kolhapur District Collector. 8.9 Precautions to be taken in handling and storage of Alcohol: Storage in tightly closed containers in cool, dark, well-ventilated area. Protect containers from physical damage. Keep heat, fire and flame away. Outside building or underground storage is recommended Risk Assessment: Environment General Assessment: The environment is at risk of exposure during transportation, storage, disposal, or destruction of ethyl alcohol. In almost every scenario, the threat of environmental exposure is contingent upon the proper handling of the chemical substance. Accidental spills, large or small, can result in fire, explosion, and possible contamination of the surrounding environmental mediums (water, soil, and air) Recommended Risk-Reduction Measures: Proper training of all transporters will reduce the likelihood of an accident resulting in a leak or spill to the environment. The correct use of DOT labeling (per the MSDS) on all containers, trucks, and rail

10 cars will enable emergency responders to react properly and quickly to any disaster thereby reducing the potential risk to the environment and to personnel. Storage of ethyl alcohol shall be segregated from incompatible chemicals to minimize the risk of cross contamination or contact. Buildings designated for storage shall be equipped with appropriate fire protection systems (alarms, sprinklers, emergency lighting, and portable extinguishers). Equipment shall be designed to meet explosion-proof standards. If a spill or leak to the environment has occurred, fire department, emergency response, and/or hazardous materials spill person should be notified immediately. Cleanup should be attempted only by those trained in proper spill containment procedures. Contaminated soils should be removed for incineration and replaced with clean soil. If ethyl alcohol should contact the water table, aquifer, or navigable waterway, time is: of the essence. It is highly soluble in water and, therefore, total containment and remediation may not be entirely possible. When such spills occur, the local and/or state emergency response authorities must be notified. A comprehensive emergency response of disaster awareness/recovery plan should be in place prior to any operations involving the use, transportation, storage, or disposal of ethyl alcohol. If ethyl alcohol is spilled or leaked, the following specific steps are recommended: a) Restrict persons not wearing protective clothing from area of spill or leak until cleanup is complete and area can be opened for normal work. b) Ventilate area and remove ignition sources. c) Absorb liquids in vermiculite, dry sand, earth, or a similar material and deposit in sealed containers. Use non-sparking tools. d) It may be necessary to dispose of ethyl alcohol as a hazardous waste. The responsible state agency or the regional office of the federal Environmental Protection Agency (EPA) should be contacted for specific recommendations.