DMP & RISK MANAGEMENT PLAN An industry with its complex of activities involving various plant machineries, raw materials, products operations, intermediates and environmental discharge has a number of associated hazards. A minor failure can lead to major failure resulting into a disaster causing heavy losses to life, property and environment. Risk assessment studies are conducted to ensure safety and reliability of any plant, through a systematic and scientific methods to identify possible failures and prevent their occurrence before they actually cause disasters and production loss. 1.1.1. Emergency: The emergency considered in this plan will refer to the occurrence of one or more of the following Fire Release of flammable liquid Release of toxic gas (Sulphur-di-oxide) Natural calamities Table 1.1 : Identification of Hazardous Areas S. No. Item/Event Location Hazard 1. Flammable liquids Storage Section Fire 2. Toxic gases Sulphitation section in sugar factory Toxic SO 2 Release 3. Bagasse Bagasses Depot Fire 4. --------- Inside the complex Major Accident: Fire 5. Structure /Building collapse Anywhere in the complex Major Accident 6. Natural calamities such as storm, earthquake etc Anywhere in the complex Major Accident Emergency Control Centre: The streamline all the coordination activities for various categories, the emergency control centre is to be established. It is desirable to establish the emergency control centre well away from the possible generally emergency site. Hence, the security office (near Factory Entrance) is declared as the emergency control centre. All communication will originate from this control centre. The emergency centre will contain following: List of important telephone numbers such as police, fire Brigade, hospital, neighboring factories and OEP team Member. Address and telephone number of directorate Industrial safety and Health, Uttar Pradesh Pollution control Board (UPPCB) Electrical inspector, Controller of Explosives (COE) Plant layout-indicating storage of hazardous materials, locations of fire fighting equipments and layout of fire hydrants and diesel generating set. Portable public address system manual siren, flood lights, torches glow sticks pick-axe, saw, nylon ropes, fire blankets, fire proximity suit, breathing apparatus, first Aid Box etc.
Emergency procedure: When an emergency occurs in the plant, the incident informer the person who first sees the mishap should inform about the emergency to the supervisor. The supervisor must inform the same to site coordinator. After confirming the message, chief coordinator will rush to Emergency control centre and alert the plant personnel through warning sounded through the waiving siren for one minute. The emergency coordination will announce the location of the emergency, requesting concerned teams to rush to the spot, and all others to clear the plant site and rush to assembly point. All team members will assemble at the spot to take over their duties under the control of the chief controller. He will give necessary instruction to teams and co-ordinate for combating the emergency. If required he will consult with the Emergency coordinators for safe shutdown/ operation plant/ section. The team leader after getting instruction from chief controller will mobilize their team members to control the emergency. They will maintain constant communication with the chief controller who will be stationed at the emergency control centre. 1.1.2. Fire and Safety Coordinator The security officer will be the fire and safety coordinator. He will assume full responsibility for All activities including organizing fire fighting manpower, equipments and appliances to control and extinguish fire/ mitigate emergency. In consultation with site coordinator, he will establish danger zone. He will assess the situation and will decide on the assistance required from state/ Municipal/ neighboring fire services. In consultation with material coordinator and safety officer, he shall update the inventory of all fire fighting / safety equipments. He shall preserve all possible evidences that would facilitate the subsequent investigation in to the cause of disaster. 1.1.3. Emergency/Rescue /Evacuation Coordinator /Site Coordinator The head of the department, in whose department, the emergency is occurred will be the Rescue / Evacuation Coordinator / Site coordinator. He will assist the chief coordinator and take the decision of shut down of the plant. He will also assist other coordinates. He will Arrange to cordon off the area of emergency Arrange for search and rescue operation Guide the fire and safety coordinator in mitigating the emergency Ensure that non-concerned personnel evacuated from the scene of emergency Will shutdown process of plant, if necessary Will direct the fire and rescue team.
Will execute all jobs to control the emergency such as isolation, diversion of the process to other areas, arrange for removal of combustible / inflammable /explosive toxic chemicals, drums, bags etc. from the emergency. Mock Drills: The success of the plan is very much dependent on planned and unplanned mock drills. Mock drills help to familiarize employees with their roles, and prove the current accuracy of the details of the Occurrence of Emergency to Chief Controller (OEP). Following events are considered under mock drills. Inform all the employees about mock drills and signals to be given. Fix the date and location of the emergency for mock drills Mock drills will be monitored by observers who will be senior officer not involved in the exercise. Ring the siren for emergency After hearing the siren all the coordinators will call their respective team members and move towards emergency control centre. Chief coordinator should alert safety/ fire team and ask them to run towards the emergency location along with appropriate firefighting equipment. The fire attendants will run to carry out their duties. Chief coordinator, on hearing from Fire / Site coordinator call the fire brigade and the same time the medical coordinator should depute medical team along with the ambulance towards the emergency site. The chief coordinator and Rescue /Emergency co-coordinator should move towards the emergency site along with engineering team and welfare team. Engineering team members should go towards the electrical panels as if, they are to be switched off and isolate the panels. Some security persons should cordon off the emergency area. Rescue/ evacuation team should work in co-ordination with security/ fire team and engineering team Engineering team leader should communicate with the public address about the mock drill. All clear signal should be raised after half an hour. 1.1.4. Risk Assessment for Bagasse and Sulfur Storage The process for manufacturing and refining sugar is a standard process. Areas of concern from hazard and risk points of view in the plant manufacturing of sugar are: Bagasse Storage Sulfur Storage SO2 generation and handling 1. Bagasse Storage: Bagasse generation per day will increase. Present area reserved for of storage will be increased from 1300 square meters to 3000 square meters.
Large quantity of bagasse stored poses the serious hazard of fire as it is easily ignitable and fire spreads rapidly. Serious fire accidents have been reported. Mitigation Measures: Following precautions should be taken to minimize risk of fire and for firefighting to contain fire in case of accident It should be ensured while routing high tension voltage lines to avoid storage of bagasse storage below & near high voltage (H.T.) transmission lines. Avoid route of electric supply cables & AC cable trenches far away from stored bagasse or bagasse heaps. Always keep raw & useful material far away from storage of bagasse area. Installation of Fire Hydrant (self auto-mode fire fighting) system around the area of bagaasse yard. Posting of proper supervision staff with necessary communication facility. Hot work, like welding, gas cutting should not be carried out near bagasse storage. Daily record of bagasse storage data, proper review of conditions taken by higher authority. Training of all the involved staff in normal & emergency operating system. Proper planning & installation of fire hydrant system around the bagasse storage yard and not depending exclusively on fire tender for fire fighting. Creating awareness among workers about sudden bagasse fire and emergency action plan will definitely avoid risks of heavy fire. In this way we can save valuable fuel & life of human being working near bagasse handling and storage. Design and Installation of Firefighting: Measures suggested: It is recommended to install fire hydrant piping system around the bagasse storage yard with fire hydrant points considering it as high hazard category [(6.7) of code IS 13039] and installing hydrant point every 30 meters and minimum 5.25 kg/cm sq. pressure should available at the remotest point. Hydrants should be located 15 meters away from the storage area boundary. Also it is recommended to install self auto-mode fire fighting system. 2. Sulphur Storage: Sulphur will be stored in a closed shed and is transfer manually to the Sulfur burner in 30-50 kg bags. Following are the hazards in storage and handling Sulfur.. A. Dust Explosion B. Fire A. Dust Explosion: As Sulphur is stored and handled in granular form, there is always some dust formation, which can lead to dust explosion. A dust explosion occurs when a fine dust in suspension in air is
ignited, resulting in a very rapid burning, and the release of large quantities of gaseous products. This in turn creates a subsequent pressure rise of explosive force capable of damaging plant and buildings and injuring people. It is generally considered that a dust explosion can only be initiated by dust particles less than 500 microns diameter. Conditions for Dust Explosion: Under the following conditions dust explosion can take place in the industry. The dust must be combustible like Sulfur, phosphorous. The dust cloud must be of explosive concentration, i.e. between the lower and upper explosion limits for the dusts. There must be sufficient oxygen in the atmosphere to support and sustain combustion. A source of ignition must be present. The dust must be fine enough to support an explosion. Mitigation Measures: Dust explosions can be prevented by ensuring that the following conditions are met: Formation and Suspensions of Sulfur dust in air are avoided. To prevent dust formation during the storage and handling of sulphur, it is necessary to take necessary precautions to avoid spillage and crushing of granular sulphur during bulk loading and unloading in the storage area. Storage shed should be constructed with a minimum number of horizontal surfaces to avoid dust accumulation. All sources of ignition are excluded. Presence of moisture helps in preventing dust explosion. B. Fire in Sulfur storage: There is a risk of fire in sulfur storage as ignition temperature is low 190 deg C. Solid and liquid Sulfur will burn to produce sulfur dioxide gas, which is extremely irritating and toxic (refer to appendix 2 & MSDS of SO2). The effects of the fire hazard itself are slight. Mitigation Measures: Smoking and the use of matches shall be prohibited in all areas where sulfur dust is likely to be present. Prominent NO SMOKING signs shall be placed around such areas. Naked flames or lights and the use of gas cutting or welding equipment is prohibited during the normal operation of the plant. Repairs involving the use of flames, heat, or hand or power tools in areas where sulfur may be present shall be made only after getting hot work permit from the authorities. Where this is not possible the sulfur shall be wetted down. Safety and Fire Fighting Tips
Always use Self Contained Breathing Apparatus (SCBA). Sulfur fires produce hazardous sulphur dioxide gas. Sulfur dioxide gas is heavier than air and will accumulate in the vapour spaces of the rail car. Small sulphur fires are easily extinguished by adding more Sulfur on top of the burning sulphur. This depletes the oxygen and smothers the fire. For larger Sulfur fires use a light water fog or CO2 to extinguish. Do not use heavy water streams as this may create Sulfur r dust which could potentially explode. 1.1.5. On-Site Emergency Plan The on-site emergency plan is supposed to be a dynamic, changing document focusing on continual improvement of emergency response planning and arrangement. A structure working on a plan, does, check and review (PDCR) cycle has been therefore suggested. A person, head of operations or factory in-charge will be deployed who will be in-charge of overall disaster management plan implementation during an emergency. 1.1.6. Occupational Health Care (OHC): Factory has occupational health care center, as per the requirement of factories act. It has one regular doctor and one visiting doctor. Full medical check up and also periodic medical examination is carried out prior to the employment of workers and contract workers. Following medical tests are carried out. 1) Blood group 2) CBC 3) Urine routine and micro 4) Blood urea 5) Blood sugar 6) Cholesterol and 7) ECG Ambulance is available 24 x 7 Two male medically trend attendant and 2 female attends are available in OHC. 30 persons are trained every year in first aid. Local Bodies, NGOS will help in relief operation, evacuation and help to police authorities in maintaining law and order.