ANNEXURE : XXIV Contd..

Transcription

1 ANNEXURE : XXIV

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3 1.0 GENERAL INFORMATION ABOUT THE FACTORY M/s Runga Mines Ltd, ( Sponge Iron Division),is situated at Karakolha P.O- Barbilin the District of Keonjhar, Odisha. It is located at a distance of approximately 4 Kms from Barbil, 16 Kms from Joda Town and 7 Kms from nearest Railway Station, Barbil The Plant occupies of Ac dec. Acres of land including cover area and in built-up area is Acres (Approx.) The main activities of the factory is to manufacture of Sponge Iron (5X100TPD). Surrounding vicinity: North side of the factory Karakhendra Village South side of the factory Karakolha Village South West of the factory Open Land East side of the factory Forest West side of the factory Open Area FACTORY ADDRESS :- M/S. RUNGTA MINES LTD. (Sponge Iron Division), At-Karakolha, Po-Barbil, Dist-Keonjhar, Odisha MAILING ADDRESS :- M/S. RUNGTA MINES LTD. (Sponge Iron Division), At-Main Road, Po- Barbil, Dist- Keonjhar, Odisha Telephone Number : Fax No Name & Designation of Occupier :- Sri M.D. Rustagi, Director Name & Designation of Manger :- Sri Charan Kumar Jena, Addl. G.M. (Works) Page 1

4 BRIEF MANUFACTURING PROCESS : Direct Reduced Iron Plant (DRI) The Plant has five (5) Rotating Kilns of 100 TPD, each, capable of producing 500 Tonne of Sponge Iron per day. Iron ore Lumps, lime and coal are fed to the kiln through conveyor belts. Coal fines (injection coal) are fed from other end of the Kiln for firing and to build up the temperature. The Kiln is rotated at set RPM, the Iron ore while traveling from feeding end to discharge end, at different temperature levels along with coal is transformed (change in chemical composition) in to Sponge Iron. At discharge end the DRI is at high temperature this to be brought down to deg. C. This is achieved by passing through transfer chute, where this is cooled with water spraying system. From cooler discharge DRI is conveyed to product separation unit, with Magnetic separator, where DRI is separated from coal fines. DRI lumps & fines are filtered by screen and stored in storage bunkers. Page 2

5 1. FLOW CHART OF DRI IRON ORE COAL DOLO- MITE COAL FINES AIR COMPRESSOR CHIMNEY KILN ESP DSC COOLER ABC DUST I - BIN HEAT EXCHANGER PRODUCT HOUSE DUST WATER PRODUCT (FINES) PRODUCT (LUMPS) SLUDGE MAGNATIC SEPARATOR MAGNATIC SEPARATOR DISPOSAL PIT SPONGE IRON (FINES) CHAR (FINES) SPONGE IRON CHAR (LUMPS) Page 3

6 2. ORGANISATION SET UP Page 4

7 3.0 MANPOWER :-Licensed manpower is 350. However at present the shift wise manpower is given below: SHIFT Period Number of employee Regular Contractor Total A hrs B hrs C hrs General Shift hrs Total Depending on the requirement, the employees are called in different shifts and few employees numbering 10 to 15 are called on duty in National / Festival holidays and off-days. 4.0 PRODUCT& BY PRODUCT PRODUCT:- SL.NO. NAME OF PRODUCT ONE TIME STORAGE QUANTITY IN TON STORAGE TYPE & CAPACITY OF STORAGE SIZE OF THE SPONGE IRON SHED 1 Sponge Iron T Under Shed of capacity 10000T (1)Length-51 Mtrs Breath-19Mtrs Height-3Mtrs (2) Length- 41 Mtrs Breath-21Mtrs Height-3Mtrs (3) Lengh-26 Mtrs Breath-19Mtrs Height-3Mtrs (4) Length-39 Mtrs Breath-26Mtrs Height-3Mtrs (5) Length- 30 Mtrs Breath-19Mtrs Height-3Mtrs Page 5

8 BYE-PRODUCT:- SL.NO. NAME OF THE BYE- PRODUCT ONE TIME STORAGE QUANTITY IN TON STORAGE TYPE& CAPACITY OF STORAGE SIZE OF THE CHAR COAL YARD 1 Char Coal 200T 5.0 INVENTORY OF RAW MATERIALS:- Sl. No. Name of the Raw Material Dump Yard of capacity T Quantity of one time storage in MT Type of Storage and capacity of storage areas 1 Iron Ore 27750MT Open Yard MT Under Shed-NIL.MT LENGTH -250 MTRS BREATH 60 MTRS HEIGHT 6 MTRS Size of the storage areas Open Yard L-110 mt,b- 40mt., Under Shed L-0,B-0,H-0 Open Yard L-70mt, B-40mt., 2 Dolomite 1200MT Open Yard-NIL.MT Under Shed1200.MT Open Yard L-..,B.., Under Shed L-25mt,B-20mt., H-3mt. 3 Coal 25800MT Open Yard 4000.MT Under Shed MT Open Yard L-50mt.,B-45mt., Under Shed L-60mt., B- 50mt,H-5mt. Under Shed L-38mt,B- 19mt,H-5mt. Under Shed L-54mt.,B- 41mt.,H-5mt. Page 6

9 6.0 INVENTORY OF HAZARDOUS SUBSTANCE:- Sl. No. Name Quantity of one time Storage 1 HSD 20 KL 20 KL 2. (i)transformer Oil inside 2MVA transformer (ii) Transformer Oil inside 1.6 MVA transformer (i) 1000.Lts. inside the transformer (ii) 800Lts. inside the transformer Type of Storage 20KL (Capacity) in Underground storage). 20KL (Capacity) in Underground storage). _ 7.0 INVENTORY OF HAZARDOUS GASES / SUBSTANCES PRODUCT / GENERATED Sl. No. Name Quantity of one time Storage NIL Type of Storage Size of the Under ground HSD tank D-2.5m L-3.8m _ 8.0 IDENTIFICATION OF HAZARDS:- Hazards are mostly manifested in the form of pool-fire or fire. Each anticipated hazard scenario associated in the unit is described along with its assessment of impact on plant and locality in the following table. : Anticipated hazard scenarios Sl. Area / Activity Hazard Impact 1. Storage and Handling of high speed Diesel (HSD) 2. In transformer. Pool fire / Fire ball may occur in case of direct contact with flame Fire may occur, short circuit/ over heating of transformer oil in side the transformer/any naked flame come in contact of the transformer oil Fire may propagate to the nearby tank and Stores. Fire will propagate within the transformer area. The ISO-RISK CONTOUR of significant heat level of 4.5 KW/M 2 experience at radius of 17.9 meters. from the source of fire hazard Page 7

10 9.0 IDENTIFICATION OF MOST CREDITABLE HAZARD SCENARIO: The anticipated hazard scenario associated with the factory as mentioned above are critically analyzed and the following scenario is identified as Most Credible Hazardous Scenario: Credible Scenario 1 : Pool Fire in High Speed Diesel Storage Tank : HAZARD ASSESSMENT Basis of Determination of most Credible Hazard Scenario Case-1 Fire Hazard in HSD Storage Tank Fire Hazard in HSD Storage Tank is considered as most Credible Scenario because of the following reasons:- HSD is a flammable liquid as per schedule-1, Part-II (b) (v) having flash point of 66 0 C and auto ignition temperature of C and explosive limit of 5-7% volume in air. So, it is susceptible to fire hazard. Whenever HSD catches fire it shall manifest in the form of pool fire. Taking into consideration of the meteorological data of the area and the above mentioned physical and chemical property of HSD, it is considered most credible Hazard scenario. In case of fire in HSD storage tank the effect distance of significant heat radiation assessed in different season is given in the table given below. METEOROLOGICAL DATA (Source- Google net) Parameter Season SUMMER RAINY WINTER Average wind speed (m/sec) Average wind direction (from) NE NE SE Humidity (%) Average ambient air temperature ( 0 C) Significant heat flux experienced at distance due to pool fire on HSD in different season. Page 8

11 Storage details Significant heat level Kw/m 2 Experience at distance in Mtrs. Indication Summer Rainy Winter HSD 20KL Causes pain if unable cover the body within 20 seconds. However blistering of the skin (2 nd degree burn) is likely caused with no lethality Minimum energy required for melting of plastic Sufficient to cause damage to the equipment. Page 9

12 FIRE MODELLING FOR HSD IN STORAGE TANK Storage detail Input data for Storage type HSD Storage Tank Summer Season Capacity 20 KL Size D-2.5m & L- 3.8m Meteorological data Google net Season Parameter Summer Rainy Winter Average wind speed m/sec 10 km/h 6km/h 2km/h Average wind direction NE NE SE Humidity (%) Average ambient air temperature ( 0 C) HEAT FLUX DATA FOR SUMMER SEASON: Distance (M) Heat Flux (KW/m 2 ) Heat propagation Curve SOFTWARE-ALOHA HSD Storage Tank- Summer season: Heat Flux in KW/m Distance in metre Significant Heat Level Value (KW/M 2 ) SIGNIFICANT HEAT LEVEL EXPERIENCED AT DISTANCE Distance (M) Indication Causes pain if unable to cover the body within 20 seconds. However blistering of the skin (2nd degree burn) is likely caused with no lethality Minimum energy required for melting of plastic Sufficient to cause damage to the equipment. Page 10

13 FIRE MODELLING FOR HSD IN STORAGE TANK Storage detail Storage type HSD Storage Tank Input data for Rainy Season Capacity 20 KL Size D-2.5 m & L- 3.8.m Meteorological data Google net Season Parameter Summer Rainy Winter Average wind speed m/sec 10 km/h 6km/h 2km/h Average wind direction NE NE SE Humidity (%) Average ambient air temperature ( 0 C) HEAT FLUX DATA FOR RAINY SEASON: Distance Heat Flux Heat propagation Curve (M) (KW/m 2 ) SOFTWARE-ALOHA HSD Storage Tank- Rainy season: Heat Flux in KW/m Distance in metre Significant Heat Level Value (KW/M 2 ) SIGNIFICANT HEAT LEVEL EXPERIENCED AT DISTANCE Distance (M) Indication Causes pain if unable to cover the body within 20 seconds. However blistering of the skin (2nd degree burn) is likely caused with no lethality Minimum energy required for melting of plastic Sufficient to cause damage to the equipment. Page 11

14 Distance (M) FIRE MODELLING FOR HSD IN STORAGE TANK Storage detail Input data for Storage type HSD Storage Tank Winter Season Capacity 20 KL Size D-2.5 m & L- 3.8.m Meteorological data Google net Season Parameter Summer Rainy Winter Average wind speed m/sec 10m/h 6km/h 2km/h Average wind direction NE NE SE Humidity (%) Average ambient air temperature ( 0 C) HEAT FLUX DATA FOR WINTER SEASON: Heat Flux (KW/m 2 ) Heat propagation Curve SOFTWARE-ALOHA HSD Storage Tank- Winter season: Heat Flux in KW/m Distance in metre Significant Heat Level Value (KW/M 2 ) SIGNIFICANT HEAT LEVEL EXPERIENCED AT DISTANCE Distance (M) Indication Causes pain if unable to cover the body within 20 seconds. However blistering of the skin (2nd degree burn) is likely caused with no lethality Minimum energy required for melting of plastic Sufficient to cause damage to the equipment. Page 12

15 Case-2 :FIRE HAZARD IN TRANSFORMER OIL IN 2 MVA TRANSFORMER Transformer oil is a flammable liquid as per schedule-1, Part-II (b)(v) having flash point of C, auto ignition temperature of >270 0 C and explosive limit of 0.7% volume in air. So, it is susceptible to fire hazard. Whenever Transformer oil catches fire it shall manifest in the form of pool fire. The significant heat flux that spread from the source in case of pool fire in transformer is mentioned below. Significant heat flux experienced at distance due to fire on transformer containing transformer oil in different season. Storage details Significant heat level Kw/m 2 Experience at distance in Mtrs. Summer Rainy Winter Indication TRANSFORMER OIL 1000L Causes pain if unable cove the body within 20 seconds. However blistering of the skin (2 nd degree burn) is likely caused with no lethality Minimum energy required for melting of plastic Sufficient to cause damage to the equipment. FIRE MODELING FOR TRANSFORMER OIL Storage detail Input data for Storage type 2 MVATransformer Summer Season Capacity 1000L Meteorological data Google net Season Parameter Summer Rainy Winter Average wind speed m/sec 10 km/h 6 km/h 2km/h Average wind direction NE NE 34 Humidity (%) Average ambient air temperature ( 0 C) Page 13

16 Distanc Heat Flux Heat propagation Curve e (M) (KW/m 2 ) SOFTWARE-ALOHA MVA Transformer: Summer Season: Significant Heat Level Value (KW/M 2 ) SIGNIFICANT HEAT LEVEL EXPERIENCED AT DISTANCE Distance (M) Indication Causes pain if unable to cover the body within 20 seconds. However blistering of the skin (2nd degree burn) is likely caused with no lethality Minimum energy required for melting of plastic Sufficient to cause damage to the equipment. FIRE MODELING FOR TRANSFORMER OIL Storage detail Storage type Capacity Meteorological data Input data for 2 MVATransformer Rainy Season 1000L Google net Season Parameter Summer Rainy Winter Average wind speed m/sec 10 km/h 6 km/h 2km/h Average wind direction NE NE SE Humidity (%) Average ambient air temperature ( 0 C) Page 14

17 Distance (M) Heat Flux (KW/m 2 ) Heat propagation Curve for Rainy Season: SOFTWARE-ALOHA MVA Transformer: Significant Heat Level Value (KW/M 2 ) SIGNIFICANT HEAT LEVEL EXPERIENCED AT DISTANCE Distance (M) Indication Causes pain if unable to cover the body within 20 seconds. However blistering of the skin (2nd degree burn) is likely caused with no lethality Minimum energy required for melting of plastic Sufficient to cause damage to the equipment. FIRE MODELING FOR TRANSFORMER OIL Storage detail Input data for Storage type 2 MVATransformer Winter Season Capacity 1000L Meteorological data Google net Season Parameter Summer Rainy Winter Average wind speed m/sec 10m/h 6km/h 2km/h Average wind direction NE NE SE Humidity (%) Average ambient air temperature ( 0 C) Page 15

18 Distance (M) Heat Flux (KW/m 2 ) Heat propagation Curve for Winter Season: SOFTWARE-ALOHA MVA Transformer: Significant Heat Level Value (KW/M 2 ) SIGNIFICANT HEAT LEVEL EXPERIENCED AT DISTANCE Distance (M) Indication Causes pain if unable to cover the body within 20 seconds. However blistering of the skin (2nd degree burn) is likely caused with no lethality Minimum energy required for melting of plastic Sufficient to cause damage to the equipment. Page 16

19 10.0 PLOT PLAN: The plot plan showing the followings is given in Annexure VI. (i) Hazard Zone (HZ) (ii) Iso-risk Contour around Hazard Zone (iii) Emergency Control Room (ECR) (iv) Assembly Point (AP) (v) Emergency Exit (EE) (vi) Fire Hydrant line Page 17

20 11. EMERGENCY COMMAND STRUCTURE Page 18

21 12.0 ROLE OF KEY PERSONS OF EMERGENCY COMMAND STRUCTURE WORKS MAIN CONTROLLER (WMC):- On being informed, rush to the scene and take overall charges of the situation Make quick assessment of the situation and decide declaration of emergency by blowing the siren in appropriate code [intermittent three times with half minutes interval] Direct respective leaders through Site Incident Controller to take control of the situation in the affected area Make continuous review and assess the possible developments to determine the extent of damage to plant and human beings Direct shut-down the plant, if necessary Orders evacuation process by consulting with key persons Ensure that casualties are receiving adequate attention Liaise with the fire services, police services and other statutory authorities Declare closure of the emergency by blowing the siren [only once long siren for 25 seconds] Issue the authorized statements to the media services Report all statutory authorities in the prescribed manner Communicate to employees about the mishap, measures taken and giving confidence to employees for avoiding recurrence of the incident by investigation and ordering preventive measures to be implemented Page 19

22 SITE INCIDENT CONTROLLER:- On hearing Emergency siren, rush to the scene and report to the Works Main Controller Carry out the instruction of Works Main Controller Make quick assess about the gravity of the situation and appraises Works Main Controller Orders Combat Team Leader, Rescue Team Leader and Auxiliary Team Leader to perform their responsibilities immediately Extend all sorts of help through different agencies to minimize the damage to human beings, plant, property and environment Report the development of the situation time to time to Works Main Controller Provide the required information to the fire brigade team for fire fighting Preserve the evidences for the subsequent inquiries COMBAT TEAM LEADER:- On hearing the emergency siren, rush to the scene with fire fighting team with sufficient equipment in the minimum possible time and report to Site Incident Controller Carry out the instruction of Site Incident Controller Ensure the team members resume their position with appropriate equipment Monitor the fire fighting operation to control the situation Ensure that the situation is controlled by arresting, spillage, fighting fire, shutting of the valve and equipment by the team in consultation with Site Incident Controller Assist the Site Incident Controller till the situation is under control COMBAT TEAM MEMBERS:- On hearing the emergency siren, rush to the scene with fire fightingequipments in the minimum possible of time and report to their team leader Carry out orders of the team leader Operate the fire fightingequipments for controlling the situation Page 20

23 RESCUE TEAM LEADER:- On hearing the emergency siren, rush to the scene and report to the Site Incident Controller Carry out the instruction of the Site Incident Controller Ensure the arrival of his team members Keep necessary equipments of first-aid for preliminary treatment Keep the ambulance ready to carry the injure persons to the hospital Ensure the proper personal protective equipments lead the team for rescue operation Inform the Works Main Controller for the developments time to time Guide the mutual aid partners for their course of action at the site Guide the non-essential persons to reach assembly point Search the missing person on the roll call basis RESCUE TEAM MEMBERS:- On hearing the emergency siren, rush to the scene with appropriate personal protective equipments and report to their team leader Carry out orders of the team leader AUXILIARY TEAM LEADER:- On hearing the emergency siren rush to the scene and report to the Site Incident Controller Carry out the instruction of Site Incident Controller Ensure the arrival of his team members Intimate statutory authorities over phone Intimate nearest Fire Station over phone Intimate mutual-aider over phone Keeps the first-aid and primary health center staff, equipment ready to take care of immediate medical needs Takes care of victims family Page 21

24 Make all arrangement like transport, other needs, arrange finance Ensure all casualties are shifted to hospital for medical treatment Keep records of casualties and provide information of the matter to Works Main Controller AUXILIARY TEAM MEMBERS:- On hearing emergency siren, rush to the scene and report to the team leader Carry out the orders of the team leader Provide immediate first-aid treatment to the victims Ensure ambulance vehicle ready Coordinate with combat team, rescue team, statutory authorities and mutual-aid partners Page 22

25 13.0 SILENT HOUR COMMAND STRUCTURE FOR DRI :- Alt. Works Main Controller-cum-Site incident Controller Shift in charge of DRI Security In-charge Combat Team 1. Sri A. Rout 2. Sri K. Behera 3. Sri R.K. Jena Rescue Team 1. Sri B. Giri 2. Sri C. Behera 3. Sri S. Mishra Auxiliary Team 1. Sri D.Das 2. Sri T. Sethy 3. Sri P. Pattnaik ROLE OF KEY PERSONS IN SILENT HOUR COMMAND STRUCTURE Silent Hour is the time when General Shift people are not available The command structure for the silent hour shall be same as during normal hour, however, during the silent hour the Shift-in-charge / Security in-charge shall act as Works Main Controller-cum Site Incidence Controller, till the arrival of the Works Main Controller Since during these hours Works Main Controller, Site Incident Controller, Combat Team Leader, Rescue Team Leader and the Auxiliary Team Leader may not be available inside the plant, they shall Page 23

26 be informed by the Security In-charge (Works Main Controller during Silent Hour) either by telephone or by sending special messenger to their residences On receiving the information the Works Main Controller, Site Incident Controller, Combat Team Leader, Rescue Team Leader and Auxiliary Team Leader shall reach the site at the earliest and simultaneously Combat Team Leader, Rescue Team Leader and Auxiliary Team Leader shall ensure the presence of their respective team members Thereafter the action plan as well as the role of key persons shall be same as the normal hour execution of Command Structure Page 24

27 14.0 ACTION PLAN FOR ON-SITE EMERGENCY: STEP NO. INITIATOR ACTION TO TAKE 1. The person noticing the emergency Inform the Security Gate and the concerned Shiftin-charge who in turn will inform Combat Team Leader immediately regarding the fire hazard. 2. Combat Team Leader (CTL) Inform Site Incident Controller (SIC) through common dialing system and rush to spot for combating the situation. Take charge of the situation, arrange for evacuation of people not directly concerned. To organize for trained personnel equipped with fire fighting appliances and call for fire tender at the place of fire. To start combating, shutdown equipments and taken steps to extinguish fire with fire fighting facilities. 3. Site Incident Controller (SIC) To find out the root cause of fire and to take necessary action for prevention of fire. Inform Works Main Controller (WMC) and will rush to Site. In case of failure electronic communication system, the standby available provision for runner with bike, will be their to pass on the command as advised. Discuss with Combat Team Leader (CTL), assesses the situation and call the Rescue Team Leader (RTL) & Auxiliary Team Leader (ATL). Inform to the Rescue Team leader, and Auxiliary Team leader and send them to site. Arrange to evacuate the unwanted persons and call for additional help. Time to time to pass information to the Works Main Controller (WMC) about the situation at site. Page 25

28 4. Works Main Controller Rush to Emergency Site and observe the ongoing (WMC) activities. Take stock of the situation in consultation with the SIC. Move to Emergency Control Room. Take decision on declaration of emergency and ask for emergency wailing siren. Advise Auxiliary Team Leader to inform the statutory authorities and seek help of mutual aid if required. Decide on declaration of normalcy of emergency after combating the situation. 5. Rescue Team (RTL) Ensure that the emergency operations are recorded chronologically. Consult with Site Incident Controller (SIC) and Rush to Emergency Site through safe route along with the team members and start the rescuing work. Shift the injured persons to hospital by ambulance after providing necessary first aid. To inform the Auxiliary Team Leader for necessary help from Mutual Aid Partners. 6. Auxiliary Team (ATL) On being directed by Works Main Controller (WMC) inform about the emergency to Statutory Authorities depending upon the situation. Seek help of Mutual Aid Partners and Coordinate with Mutual Aid Partners to render their service if required. To take role call to find out the missing persons if any. Page 26

29 Arrange to inform the relatives of Casualties. Take care of visit of the authorities to the Emergency Site. 7. Team Members Each of the team members should follow the instruction of concerned team leader to mitigate the emergency ACTIVATION AND CLOSING PROCEDURE FOR ON-SITE EMERGENCY Anybodynotices FIRE, shout FIRE, FIRE, FIRE and informs to Shift-in-charge [or Smoke detector indicates fire alarm installed in the emergency control room] Being informed about fire, the Shift-in-charge informs Works Main Controller and Site Incident Controller On hearing about the fire, Works Main Controller and Site Incident Controller rush to the scene and make quick assessment of the situation On quick assessment of the situation, the Works Main Controller rush to the emergency control room and declare emergency by blowing appropriate siren code [intermittent three times with half minutes interval] On hearing of Emergency siren the key personnel of Emergency Combat structure perform their duties and responsibilities as per the worksheet During the emergency operation, the Works Main Controller keeps records of activities carried on, supervises overall, maintain liaison with mutual aiders, statutory authorities After being controller the situation, the Works Main Controller declares normalcy by blowing appropriate siren [three minutes continuously] Page 27

30 ANNEXURE-I DETAILS OF FACILITIES AVAILABLE Emergency Control Room is the place from where all emergency management operations are directed and coordinated. It is also the place from where all communications will be established, with outside agencies and district authorities. Facilities available:- Mobile phone -2 nos. Wind direction and speed indicator 1 (One) No. Windsock 1 (One) no. Wallboards for fixing up drawings and drawing pins. Flip charts, drawing sheets and sketch pens Switch for actuating the siren, drinking water arrangement, tables, chairs, etc. Details of address and telephone numbers of key personnel of emergency command structure, statutory authorities and mutual aiders Worksheet of key personnel of emergency command structure Applicable siren code Additional information Safety manual Material safety data sheets of HSD & Transformer Oil List of emergency telephone numbers (external and internal) Local P & T telephone directories List of people working in the installation, location wise List of residential addresses of employees / contract workers and casual workers Equipment :- Emergency lights 6 (Six) nos. Sufficient number of torch lights 12 (Twelve) nos. Self contained breathing apparatus 1 (one) no. Page 28

31 Personal protective equipment Helmet- 600 nos. ; Safety boot- 600 pairs ; Safety gloves-200 pairs ; Safety goggles-45 nos. ; Nose mask-150 nos. ; Welding glass-15 nos. ; Welding helmet- 15 nos. Red / Green flag 6 nos. each Assembly Points:- In an emergency, it will be necessary to evacuate people from the affected zones or the zones likely to be affected, to safe areas. The safe areas are identified and designated as Assembly Points (AP). The location of the assembly point is the vacant space shown in the Plot Plan. Arrangements for taking head count of persons, reconciling the head count with the attendance rolls, temporary shelter and further evacuation if necessary to safer place outside factory campus can be made. Escape Routes:- ESCAPE ROUTES AND WIND SOCKS Escape routes are those that allow reasonably safe passage of persons from the work areas to the Assembly Point. These routes would be different for different wind directions. For fire explosion scenarios, evacuation decisions and escape routes are to be based on the distances at which heat radiation flux reaches a level harmful to human beings (4.5KW/m 2 for heat radiation). Escape routes are marked on the drawings that would facilitate site incident controller to precisely announce the routes in case of evacuation. Wind Socks:- During emergencies, the knowledge of exact wind direction helps the factory personnel to decide on the escape route to be taken for safe evacuation of personnel and also the safe assembly point and Emergency Control Centre. Therefore, the windsock is provided at the top-most point of the factory building (at TG Building) for easy identification of the wind direction. COMMUNICATING THE EMERGENCY AND MEDICAL AID For communicating the declaration of emergency and evacuation decision to the plant personnel, it is envisaged that the siren would be utilized. Declaration of emergency :- Intermittent three times with Half-minute interval Normal factory siren :- Continuous for 30 secs. All-clear signal :- Continuous for 3 mins. Page 29

32 Emergency Medical arrangement:- The first-aid box is available in each department 40 nos. First-aid boxes are maintained in each department Adequate stock of essential medicines, bandages and other appliances are being maintained. Self Carrying compressed Air breathing apparatus It is always kept intact to use the same for mitigating chlorine leak from the system. Fire Hydrant System Fire Hydrant System is provided at different locations inside the plant as shown in plot plan. Fire Hydrant hoses are 63mm. diain size.two motors along with two suitable pumps which can discharge 60 m 3 of water per hour are provided to main header to maintain a pressure of 7 Kg/cm2. In case of temporary power failure, the fire pumps are run through DG sets. Two water reservoirs having capacity of 40000ltr. and ltrs are supplying water to the fire main line. Fire Extinguishers Required types of fire extinguishers have been provided at different locations of the plant as given below :- Sl. No Place Type of Fire extinguisher Number 1 Control Room CO Electrical MCC CO D.G. Room CO2 Dry Powder Type Quality Control Room Dry Powder 1 5 Store Room Dry Powder 2 6 Weigh Bridge Dry Powder 1 7 Mechanical Department Dry Powder 1 8 HSD Tank area Foam Type 4 Fire Buckets Fire buckets filled with dry sand are provided in different locations of the plant. Page 30

33 Siren Company has Siren/ hotter arrangement, which can be activated manually during fire related/gas leakage emergency. Communication Public address system and EPABX telephone is available for effective communication inside the plant. Telephone directory is available in the entire department. First Aid Box Company has provided First Aid boxes with required first aid medicines at different locations inside the plant for any injury. First aid boxes are being checked once in a month and medicines are replaced. Fire Tender Availability of own fire tender. In case of in adequacy mutual aid help is taken from nearby adjacent industries as well as from Govt. fire station. General Safety Precaution to Hazards: 1. Wear only cotton/approved work clothes while on duty in the plant. 2. Don't resort to short cuts. 3. Don't attempt to operate any equipment to which you are not specifically assigned. 4. Don't use the defective equipments of any kind. 5. Use the PPE to work safely. 6. Insist your fellow workers to observe the safety rules. 7. Take instruction from your superior before starting any new works. 8. Report all injuries/dangerous occurrence to your superior. 9. Curing emergency be strictly guided by the emergency action plan. FIRE ALARM SYSTEM There is an electric siren, installed at emergency control room, which warns to workers and employees in case of any emergency stand by arrangement in case of power failure DG set is available for the fire alarm system. Page 31

34 ANNEXURE-II MUTUAL AID Page 32

35 ANNEXURE-III DETAILS OF TELEPHONE NUMBERS OF KEY PERSONNEL OF EMERGENCY COMMAND STRUCTURE Sl. No. Name & Designation of Key Personnel 1 Mr. C.K. Jena Addl.GM (Works) 2 Sri A.K. Raut Sr.Manager (Electrical) 3 Sri Suresh Mohapatra AGM (Process) 4 Sri Sailendra Kumar Barik AGM (Mechanical) 5 Sri S. Bhattacharya Sr. Manager (Comml.) 6 Sri TusharSahoo Asst. Engineer (Mechanical) 7 Sri J.B. Mohapatra Dy. Manager (Q.C) 8 Sri P.C. Swain Asst. Er. Mechanical 9 Sri S. Pradhan Asst. Manager, Personnel 10 Sri A.R.N. Behera Designation as per Emergency command structure TELEPHONE / CELL NEMBER Works man Controller Works Main Controller (Alt.) Site Incidence Controller Site Incidence Controller (Alt.) Combat Team Leader Combat Team Leader (Alt.) Rescue Team Leader Rescue Team Leader (Alt.) Auxiliary Team Leader Auxiliary Team Leader (Alt.) Pharmacist 11 Security Incharge Worksmain Controller-cum Site Incident Controller Page 33

36 ANNEXURE-IV DETAILS OF TELEPHONE NUMBERS OF STATUTORY AUTHORITY Sl. No. AUTHORITY TELEPHONE NUMBER (OFFICE) 1 Collector and District Magistrate, , Keonjhar 2 Addl. District Magistrate (General) , Keonjhar 3 Addl. District Magistrate (Addl.), , Keonjhar 4 Superintendent Police, Keonjhar , Addl. Superintendent Police, Keonjhar Emergency Officer, Keonjhar Fire Service, Barbil, Joda Chief Medical Officer, Keonjhar Police Station, Barbil 100/ Asst. Director of Factories & Boilers, Keonjhar 11 Director of Factories & Boilers, Odisha, Bhubaneswar Page 34

37 ANNEXURE-V MATERIAL SAFETY DATA SHEET FOR HIGH SPEED DIESEL 1. Physical State Liquid 2. Colour Straw red 3. Specific Gravity Flash Point C Boiling Point C Auto ignition Temperature C Vapor Pressure < 1 mm 8. Solubility NO 9. Explosive Limit (% Volume in air) 5-7 A. POTENTIAL HEATH EFFECTS Inhalation: - Irritation of the upper respiratory tract and eyes, with possible euphoria, dizziness, headache, disco ordination, ringing in the ears, convulsions, coma, and respiratory arrest. Ingestion: - Irritation of the mucous membranes of throat, esophagus and stomach which may result in nausea and vomiting; central nervous system depression may occur, if absorbed (see inhalation symptoms above). If aspirated, chemical pneumonitis may occur with potentially fatal results. Possible kidney and liver damage may be delayed. Skin Contact: - Defeating of the skin may occur with continued and prolonged contact. Irritation and burning sensation may occur on exposure to the liquid or mists. Eye Contact: - Severe burning sensation with temporary irritation and swelling of lids. Page 35

38 B. FIRSTAID MEASURES Inhalation: Get person out of contaminated area to fresh air.!f breathing has stopped resuscitate and administer oxygen if readily available. SEEK MEDICAL ATTENTION IMMEDIATELY. Ingestion: Never give anything by mouth to an unconscious person. If swallowed, do not induce vomiting. If vomiting occurs spontaneously, keep airway clear. SEEK MEDICAL ATTENTION IMMEDIATELY. Skin Contact: - Wash contaminated areas with plenty of soap and water. A soothing ointment may be applied to irritated skin after thoroughly cleansing. Remove contaminated clothing and footwear. Eye Contact: - Immediately flush eyes with large amount of water for at least 15 minutes holding lids apart to ensure flushing of the entire eye surface. SEEK IMMEDIATE MEDICAL ATTENTION. Note to Physician: Do not induce vomiting, use gastric lavage only. Aspiration of liquid into the lungs could result in Chemical pneumonitis. Use of adrenaline is not advised. Treat symptomatically. C. FIRE FIGHTING MEASURES Fire Fighting Instructions:- Use water fog, C02, foam, dry chemical or Halon to extinguish. Keep personnel removed from and up-wind of fire. Cool adjacent structures and storage drums with water spray. Evacuate area. Prevent runoff from fire control dilution from entering streams or drinking supply. D. HANDLING AND STORAGE Store only in approved containers. Protect containers against physical damage. Outside or detached storage is preferred. Separate from oxidizing materials. Store in cool, well ventilated area of noncombustible construction away from possible sources of ignition. Keep away, from incompatible materials. Product Use: This product is intended for use as a fuel in engines and heaters designed for kerosene or diesel fuels, and for use in engineered processes. Use in other applications may result in higher exposure; and require additional controls, such as local exhaust ventilation and personal protective equipment. Page 36

39 E. PERSONAL PROTECTION Airborne Exposure Limits: None established. Ventilation System: Not expected to require any special ventilation. Personal Respirators: Respiratory protection is not required unless product is sprayed or heated. Use approved respiratory protection following manufacture's recommendations where spray, mists, or vapors may be generated. Supplied air respiratory protection is required for IDLH areas. Skin protection: Wear protective glove and clean body-covering clothing. Eye protection: Face shield and goggles or chemical goggles should be worn where mist or spray may be generated, and where splashing occurs. Shower and eyewash facilities should be accessible. ACCIDENTAL RELEASE MEASURES If material is spilled, steps should be taken to contain liquid and prevent discharges to streams or sewer systems and control or stop the loss of volatile materials to the atmosphere. Spills or releases should be reported, if required to the appropriate local, state and federal regulatory agencies. Small Spills: Remove ignition sources. Absorb spilled material with non-combustible materials such as cat litter, dirt, sand, or petroleum as sorbent pads/pillows. Do not use combustible materials like rags, wood chips, or saw dust. Remove contaminated materials to an appropriate disposal container. Large Spills: Remove ignition sources. Dike spill area with sand or dirt to contain material and cover sewers/drains. Remain upwind and keep unnecessary people away. Contact trained emergency response team for cleanup. Remove liquid using grounded suction pumps, isolate hazard area and deny entry. G. TRANSPORTATION It is transported as combustible liquid following the transport rules of hazardous chemicals. Page 37

40 MATERIAL SAFETY DATA SHEET DURALIFE TRANSFORMER OIL- ALL GRADES MSDS Number: PRODUCT AND COMPANY IDENTIFICATION Revision Date: 8/09/2010 Product Name: DURALIFE TRANSFORMER OIL- ALL GRADES 2. HAZARDS IDENTIFICATION: IMMEDIATE HEALTH EFFECTS: EYE: Not expected to cause prolonged or significant eye irritation. SKIN : Contact with the skin is not expected to cause prolonged or significant irritation. Not expected to be harmful to internal organs if absorbed through the skin. INGESTION: Not expected to be harmful if swallowed. INHALATION: This product is not expected to pose an inhalation hazard under conditions of normaluse. This product has a low vapor pressure and is not expected to present an inhalation hazard at ambient conditions. Caution should be taken to prevent aerosolization or misting of this product. Acute and chronic overexposures generated under unusual conditions may be irritating to the respiratory tract. 3. FIRST AID INFORMATION: EYE CONTACT: Immediately flush eyes with large amounts of water and continue flushing until irritation subsides. If material is hot, treat for thermal burns and seek immediate medical attention. SKINCONTACT: No treatment is necessary under ordinary circumstances. Remove contaminated clothing. Wash contaminated area thoroughly with soap and water. If material is hot, submerge injured area in cold water. If victim is severely burned, remove to a hospital immediately. INHALATION: This material has a low vapor pressure and is not expected to present an inhalation exposure at ambient conditions. If vapor or mist is generated when the material is heated, and the victim experiences signs of respiratory tract irritation, remove to fresh air. INGESTION: No treatment is necessary under ordinary circumstances. Do not induce vomiting. This material does not present any known ingestion hazard. Page 38

41 4. FIRE AND EXPLOSION INFORMATION: Flammable Properties: Flash Point:> 293 o F (145 o C) Test Method: ASTM D 92 (C.O.C.) Flammable Limits in Air Upper Percent: NA Lower Percent: NA Auto-ignition Temperature:> 270 o C Test Method: NA NFPA Classification: Health: 0 Flammability: 1 Reactivity: 0 Extinguishing Media: Use dry chemical, foam, or carbon dioxide. Fire Fighting Measures Special Fire Fighting Procedures and Equipment: Water may be ineffective but can be used to cool containers exposed to heat or flame to prevent vapor pressure buildup and possible container rupture. Caution should be exercised when using water or foam as frothing may occur, especially if sprayed into containers of hot, burning liquid. Unusual Fire and Explosion Conditions: Dense smoke may be generated while burning. Carbon monoxide, carbon dioxide, and other oxides may be generated as products of combustion. Hazardous Combustion By-Products : None 5. ACCIDENTAL RELEASE MESURES: Protective Measures: Eliminate all sources of ignition in vicinity of spilled material. Accidental Release Measures : Stop the source of the leak or release. Clean up releases as soon as possible, observing precautions in Exposure Controls/Personal Protection. Contain liquid to prevent further contamination of soil, surface water or ground-water. Clean up small spills using appropriate techniques such as sorbent materials or pumping. Where feasible and appropriate, remove contaminated soil. Page 39

42 6. HANDLING AND STORAGE INFORMATION: Handling: Fire extinguishers should be kept readily available. STORAGE: Do not transfer to unmarked containers. Store in closed containers away from heat, sparks, open flame, or oxidizing materials. See also additional information section below. Empty Container Warnings DRUMS: Empty drums should be completely drained, properly bunged and promptly returned to a reconditioned drum, or properly disposed. Empty containers retain product residue and can be dangerous. PLASTIC: Do not reuse this container. Empty container may retain product residues. 7. EXPOSURE CONTROLS/PERSONAL PROTECTION: Exposure Limits and Guidelines: This product does not contain any components with OSHA or ACGIH exposure limits. Personal Protective Equipment EYE/FACE PROTECTION: No special eye protection is normally required. Where splashing is possible, wear safety glasses with side shields as good safety practice. SKIN PROTECTION: No skin protection is required for single, short duration exposures. For prolonged or repeated exposures, use impervious clothing (boots, gloves, aprons, etc.) over parts of the body subject to exposure. If handling hot material, use insulated protective clothing (boots, gloves, aprons, etc.). Launder soiled clothes. Properly dispose of contaminated leather articles including shoes, which cannot be decontaminated. RESPIRATORY PROTECTION: Respiratory protection is not required under conditions of normal use. If vapor or mist is generated when the material is heated or handle, use an organic vapor respirator with a dust and mist filter. All respirators must be NIOSH certified. Do not use compressed oxygen in hydrocarbon atmospheres. PERSONAL HYGIENE: Always wash hands and face with soap and water before eating, drinking, or smoking. Consumption of food and beverage should be avoided in work areas where this product is present. ENGINEERING CONTROL/WORK PRACTICES: Use in a well-ventilated area. If user operations generate an oil mist, use process enclosures, local exhaust ventilation, or other engineering controls to control airborne levels below the recommended mineral oil mist exposure limits. Page 40

43 8. PHYSICAL AND CHEMICAL PROPERTIES: Appearance : Bright Yellow Pour Point : < -40 o F (- 40 o C) Odor : Petroleum mild Solubility in Water: Negligible in water Physical State : Liquid Vapor Pressure : < 0.1 mm Hg Boiling Point : > 482 o F (250 o C) Vapor Density (air=1): NA Melting Point : o F (-51 o C) ph: NA Specific Gravity : < 1 40 o C: 12 c St M 9. STABILITY AND REACTIVITY INFORMATION: Chemical Stability : Stable Condition to Avoid : High heat and open flames Incompatible Materials to Avoid : May react with strong oxidizing agents 10. TOXICOLOGICAL INFORMATION: Primary Eye Irritation : NA Primary Skin Irritation : NA Acute Dermal Toxicity : NA Subacute Dermal Toxicity : NA Dermal Sensitization : NA Inhalation Toxicity : NA Oral Toxicity : NA Mulagenicity : NA 11. DISPOSAL INFORMATION: Regulatory Information : All disposals must comply with federal, state, and local regulations. The material, if spilled or discarded, may be a regulated waste. Refer to state and local regulations. Department of Transportation (DOT) regulations may apply for transporting this material when spilled Waste Disposal Methods : Waste material may be landfilled or incinerated at an approved facility. Materials should be recycled if possible. Page 41

44 12. TRANSPORTATION INFORMATION: Highway / Rail (Bulk) : Highway / Rail (Non-Bulk) : Not Regulated Not Regulated The DOT description is provided to assist in the proper shipping classification of this product and may not be suitable for all shipping descriptions.health and Environmental Label Language CAUTION : Contains Petroleum Lubricant. Repeated skin contact can cause skin disorders. ATTENTION: Used motor oil is a possible skin cancer hazard based on animal data. Repeated exposure to oil mist in excess of the OSHA limit (5mg/m3) can result in accumulation of oil droplets in pulmonary tissue. PRECAUTIONARY MEASURES: Avoid excessive & prolonged skin contact. Wash thoroughly after handling. Avoid generation and inhalation of oil mists. INSTRUCTIONS IN CASE OF FIRE OR SPILL: In case of fire, use water spray, foam, dry chemical or carbon dioxide. Water spray may be ineffective, but can be used to cool containers. In case of spill, do not use water, soak up with absorbent material. ANNEXURE-VI The details plot plan is attached separately, showing the followings is given in Annexure VI. (i) Hazard Zone (HZ) (ii) Iso-risk Contour around Hazard Zone (iii) Emergency Control Room (ECR) (iv) Assembly Point (AP) (v) Emergency Exit (EE) (vi) Fire Hydrant line Page 42