RISK ASSESSMENT

Risk Assessment & Damage Control

Risk assessment is the determination of quantitative and qualitative value of risk
related to a concrete situation and a recognized threat. Activities requiring assessment
of risk due to occurrence of most probable instances of hazard and accident are both
onsite and off-site.
Maximum Credible Accident Analysis (MCA)
Increasing fatal accidents that have occurred during transportation, Handling,
operation, Process have to be taken into consideration and, therefore have prompted
the Ministry of Environment and Forests & Climate Change (MoEFCC), Government of
India, to make Risk Assessment a mandatory requirement for all Industry sector.
MCA stands for Maximum Credible Accident or in other words, an accident with
maximum damage distance, which is believed to be probable. MCA analysis does not
include quantification of the probability of occurrence of an accident. In practice the
selection of accident scenarios for MCA analysis is carried out on the basis of
engineering judgment and expertise in the field of risk analysis especially in accident
analysis.
Hazard Identification & Risk Assessment (HAZID-HIRA)
The steel manufacturing industry is labor intensive and uses large scale and potentially
hazardous manufacturing processes. The industry experiences accident rates that are
high compared with some other manufacturing industries. Some examples of such
hazards likely to occur in proposed Sponge Iron Plant, Induction Furnace, Continuous
casting machine, Billet Caster, Mini Blast furnace, Rolling Mill, CPP at M/s. Shah sponge
& Power Ltd are given below (these mainly impact on those working within the
industry, although health hazards can also impact on local communities):
• Fire
• Explosion
• Physical Hazards due EOT cranes, conveyor system, material handling
• Fugitive Dust of Raw Material Handling at charging bay, storage yard, Crusher, DRI
Kiln, Billet Caster
• Occupational health issue of Fly Ash, Slag crushing, Sand, Stone dust, Gypsum,
Limestone, dolomite exposure
• Collapse of Structures/Fall of Material, stacking failure
• Loading/ Unloading /Packaging Operations failures
• Cleaning operation failures/ Cyclone Jamming
• Electrocution/ Electrical Hazards
• Accidental Spillage of hot molten metal & Diesel fuel
Identification of source of Ignition at M/s. Shah Sponge & Power Ltd
• Creation of hotspots during operation or maintenance of Process equipment
• Self-ignition of hot material
• The electrical Discharge(thunderbolt, electrostatic charges, short circuits), Static
charge
Identification of sources of Fire & Explosion at M/s. Shah Sponge & Power Ltd
• Oil and Lubricant Room (spillage)
• Fine Coal Hoppers
• Coal Storage area
• Electrical Substations (Short circuit)
• AFBC Boilers
• Induction Furnace
Thermal radiation
Table 1 Enlists damage consequences due to different Heat Loads are given below:
Table 1 List of Damages Envisaged at Various Heat Loads
Sl. Heat Type of Damage Intensity
No. loads Damage to Equipment Damage to People
(kW/m²)
1 37.5 Damage to process 100% lethality in 1 min.
equipment 1% lethality in 10 sec
2 25.0 Minimum energy required 50% Lethality in 1 min.
to ignite wood Significant injury in 10 sec
3 19.0 Maximum thermal --
radiation intensity allowed
on thermally unprotected
equipment
4 12.5 Minimum energy required 1% lethality in 1 min
to melt plastic tubing
5 4.0 -- First degree burns, causes
pain for exposure longer
than 10 sec
6 1.6 -- Causes no discomfort on
long exposures
Source: World Bank (1988). Technical Report No. 55: Techniques for Assessing Industrial
Hazards. , Washington, D.C: The World Bank.

Physical Hazards onsite

• Dust Exposure at coal crushing area
• Dust Exposure of Fly Ash, Bottom Ash
• Dust Exposure of minerals, Slag (SMS), Gasifier
• Dust Exposure of Sand and Stone dust
• Accident due to EOT crane, Conveyor system, Material handling
• Slip/Trip/ Fall due to improper stacking of material
Loading/Unloading operation/ Storage
• Approach of heavy good vehicles for unloading material
• Work inside hopper/ Silo for unblocking of mouth
• Excessive Dust during Loading/unloading operation
• Airborne dust
• Conveyor moving parts
• Cleaning of overflows
• Unauthorized passages ,travelling over transportation system
• Motor overloading
• Unclean platforms causing staggering and falls
Silo cleaning operation
• Work in confined spaces
• Falling of material
• Falling of personal from working platform
• Exposure to dust
• Use of lifting equipment
• Use of hand held work equipment during cleaning
Steel Melting Shop
The main hazards arise out of the use of hot metal and oxygen at the spillage of hot
metal cause serious burn injuries and fires. Severe explosions are also caused due to
hot metal falling over a pool of water, resulting in injuries to persons, fire and damage
to equipment due to flying of hot splinters & splashing of liquid metal/slag.
Sudden break out of molten metal result in heavy explosions, due to their
coming in contact with water, thereby causing serious burn injuries to persons and
damage to equipment.
Electrical Hazard due to Dust
Electrical equipment such as motors, circuit breakers, transformers, and switchgear
can produce sparks and ignite dust clouds and hybrid dust/air mixtures in the vicinity.
Reference is taken from CCPS Guidelines for safe handling of Bulk solids.
• Ingress of dust into enclosures with subsequent ignition causes smoldering or
burning (fires)
• Dust that enters an enclosure will settle out as layers on internal surfaces and
become heated
• Electrically conductive dusts causes short-circuiting when deposited on exposed
electrical components and circuits
• Abrasive and/or corrosive dusts damages components of electrical equipment
 • Electric shock
Captive Power plant (CPP Unit) expansion
• Steam Handling and Pressure drop(Steam Explosion)
• Fly Ash handling
• Exposure to High temperatures
• Physical Hazards
• Blast overpressure
• Design failure
• Failure of Safety Relief devices
• ID fan/PA fan/SA fan failure
• Circulation line failure
• Turbine system failure
• Furnace bed maintenance for FBC Boiler
• Dosing System Failure( HP and LP)
• Failure of fuel firing system / Burner Management system(BMS)
• RCC chimney blockage
• Temperature drop and failure of Air cooled condenser, Low pressure(LP) and High
Pressure(HP) heater and Drain cooler
• Failure of re-circular system
• Pump failure (Boiler feed, HSD unloading, Transfer)
Waste Heat Recovery Boiler (WHRB Unit)
• Blast Over pressure
• Steam Pressure drop
• Leak , Catastrophic rupture in gas lines
• Temperature drop in Boiler, Pre heater
• Process failure
Table 2 Site Specific HIRA for Shah Sponge and Power Limited

S. Activity Hazard Risk Hazard Proposed Safety system

No. Potential
1 Raw material Handling 1. Preparation of SOP and SMP and
Training manuals
1.1 Unloading of Dust, Respiratory Moderate
2. Provide adequate training to
material from collision of problems
operators
trucks trucks and injury to
3. Conduct regular safety audits
personnel
and rectify safety issue and
1.2 Shifting of Dust , Injury to Moderate monitor safety compliance
material by collision, personnel reports
mobile overloading 4. Ensure use of PPE
equipment's
 S. Activity Hazard Risk Hazard Proposed Safety system
No. Potential
1.3 Transportation Dust, Respiratory Light
of material in overloading, problem and
conveyors injury to
personnel
2 Blast furnace 1. Hot protection suit to be worn
by personnel working with hot
2.1 Tapping of hot Spillage of Burn injury High
metal
metal hot metal
2. Follow work permit, SOP and
2.2 Working in gas Gas leakage Gas poison , High SMP.
pipeline gas 3. CO gas monitoring system for
explosion gas leakage.
4. Purging with inert gas while
2.3 Operation Electrical Body injury High working in Gas Lines
Area Hazard 5. Wear gas masks during working
in gas line
6. Firefighting system in operation
7. Reliable and selective digital or
microprocessor based
electromagnetic protective
relays would be incorporated in
the electrical system
3. Captive Power Plant (CPP)
3.1 Boiler Area Exposure to Burn injury, Moderate 1. Insulating clothing, body suits,
High Body injury aprons etc. of appropriate
temperatures materials
& Blast 2. Preparation of SOP and SMP and
overpressure Training manuals
3. Fire fighting system in operation
3.2 Ash Handling Dust Respiratory Moderate
4. For high dust levels, wear: a Full-
Area Exposure/ problem and
face Class P3 (Particulate) or an
Dust fumes injury to
Air-line respirator.
personnel
5. For inhalation risk exists, wear: a
Class P1 (Particulate) respirator.
6. Provide Onsite rescue equipment
4 Induction furnace with Continuous Caster Machine 1. Using inert gas to prevent
(CCM), Ladle Refining Furnace, Reheating Furnace oxidation
2. safety distance of 4 mtr from
4.1 Shifting of Collision, Injury to Moderate
the delivery spout are suggest
material by overloading personnel
to work near molten metal
mobile
equipment
 S. Activity Hazard Risk Hazard Proposed Safety system
No. Potential
4.2 Tapping of Spillage of Burn injury High 3. Hot protection suits to be worn
liquid steel liquid steel Physical by personnel working with hot
and slag in Hazards metal
Ladle 4. Scarp must be free from
contamination. Face
4.3 Radiation Scarp, testing Fatal disease High
mask/shield should be
of equipment
provided.
4.4 Explosion Molten Burn, injury, High 5. Follow work permit SOP and
metal, Death SMP.
6. Complete dryness of material
4.5 Operation Electrical Body injury Moderate prior to contact with liquid iron
Area (Shed) Hazard and steel separation of
4.6 CCM Occupational Burn Injury Moderate flammable gas and combustible
Operation Hazard Physical material, ensure that scrap used
Area Hazard in process should not be
contaminated with hazardous
materials. Storage structure
made of noncombustible
material provide equipment
grounding for minimization of
static electricity hazard. All the
motor must be spark proof.
7. Firefighting system
8. Reliable and selective digital or
microprocessor based
electromagnetic protective
relays would be incorporated in
the electrical system
9. Vital connections e.g. water,
power, etc., would be regulated
as per requirement
5 Rolling mill 1. Preparation of SOP and SMP
and Training manuals
5.1 Roll mill Hot object Burn injury Moderate
2. Provide adequate training to
operation
Oil Cellar Fire Moderate operators
3. Conduct regular safety audits
5.2 Cutting of re Flying off Body injury Moderate and rectify safety issue and
bars in shear sharp metals Physical monitor safety compliance
machine Hazards reports
4. Provide firefighting systems
5. Nip of rolls must be guarded
6. Rotating Machine part must be
guarded
 S. Activity Hazard Risk Hazard Proposed Safety system
No. Potential
7. Lock out/tag out must be
planned
8. Ensure personnel wear PPE
6. Producer Gas Plant 1. Insulation of hot parts of system
- Insulation of double sluice
6.1 Operation Fire Hazard problems of Moderate
filling device
Area Explosion headache,
- Installation of back-firing valve
Hazard dizziness and
in gasifier inlet
even death
2. ventilate cold system before
igniting the fuel.
6.2 Coal Feeding Occupational Dust Moderate 1. Ensure personnel wear PPE like
Hazard Exposure dust masks, safety glasses, etc.
Avoid overloading, provision of
closed conveyor system

Natural and Manmade Calamities which can lead to Emergency

Earthquake
The East Singbhum area falls under the seismic zone-II, which is the Low risk quake
upto magnitude 4.1 and may trigger into a technological disaster, includes collapse of
old structures, buildings leading to fire and explosion. Earthquake cannot usually be
forecasted and therefore precautions immediately prior to such event are not usually
possible. Emergency recovery plan has been considered by the emergency
management team as per the situation and site conditions as follows in Table No 7.7.
Table 3: Emergency recovery plan
Step Activity Action By
Preparedness • Constitute Emergency Response Plant Key Person
Team
• Identify ECC, if the identified ones are
damaged
• Control centers to be equipped with
− Alarming
− Communication facilities
− Emergency vehicles/ equipment
− List of emergency contacts &
suppliers
− Medical facilities
Action during • Do not panic. Raise alarm Individual(s)
 Step Activity Action By
effective • Avoid standing near to windows,
period external walls
• Stand near the columns or duck
under sturdy furniture.
• Assemble at emergency assembly
point as there may be aftershocks
Action after • Assess situation and initiate shut Main Controller,
effective down of plants (if required) Incident Controller,
Period • Initiate search & rescue (if required) Site Incident
(Establish Controller, ,
• Evacuation of people.
Emergency Coordinators – Fire &
• Recovery/ Rehabilation Work
Control Security, Safety,
• Medical care for the injured. Material and Medical
Center. Site
• Supply of food and drinking water.
Main
• Temporary shelters like tents, metal
Controller to
sheds etc.
direct
all activities) • Repairing lines of communication
and information.
• Restoring transport routes
• Take head count
• Activate emergency plan as situation
demands
• Assess damage
Storm
The contingency actions during storm shall be based on the weather forecasts
obtained from meteorological stations and the local meteorological department.
Some of the important actions to be carried out are as follows:
Prior to Storm
• Communication with the local meteorological department.
• Maintain distances from storm in order to execute preparatory actions in a
shorter time.
• Considering the consequences about the emergency might have on operations
and personnel.
• Review all operations carefully to ensure that systems in jeopardy are taken care
of or shut down.
• Ensure the readiness of first aiders, emergency vehicles, medical centre,
medicines etc.
• Metallic sheets, loose materials, empty drums and other light objects shall be
properly secured.
• Flush the drainage systems.
During Storm
• Remain calm.
• Avoid going outdoors.
• Do not seal the office completely as the suction created by the difference in
atmospheric pressure inside and outside can rip open a window or door by
breaking window glass panes.
After the Storm
• Do not touch electric lines.
• Stay away from the disaster area.
• Take special precautions in driving vehicles since the under-pavement could cave
in due to the weight of automobile.
Flood
Jharkhand faces major floods mainly due to Flash Floods especially in East and West
Singhbhum, Jamshedpur, Saraikela, Ranchi. Flood control measures will be taken as
required to maintain the Plant safety. Flash flood has caused severe damages to
houses, roads, bridges and culvert. Sahibgunj district was hit by massive Flood in the
year 2008. Many villages on the right bank of river Ganga have been threatened due
to erosion of the bank of the river Ganga. Flash flood in Ranchi and Jamshedpur are
mainly caused due to blockage in drainage pattern of these cities and settlement of
unauthorized colonies in low line areas.
Air Raid
Air raid warning is obtained from the District Emergency Authority or Defence
Authorities, during which total blackout of the entire complex should be considered.
Some of the contingency actions to be considered during an air raid are as follows:
• The Aviation Lights installed on highest point inside the factory shall be switched
off.
• All the lighting on the Streets shall be put off.
• All the plant lighting shall be put off.
• Brown curtains shall be provided for all windows inside the building.
• Other emergency actions shall be followed in addition as per the general
procedure.
Food and Water Poisoning
Food and water poisoning to a no. of persons, due to canteen food or other means, is
another scenario which can leads to major emergency. In this case Medical Officer
would be informed immediately by the Main Controller at site and then to incident
Controller(IC) and Site Controller (SC). In such situation doctors will act and if situation
demands additional help such as ambulances, doctors and medicine would be
arranged from nearby factories and hospitals.
Fire& Explosion Index
Fire and Explosion Index (FEI) is useful in identification of areas in which the potential
risk reaches a certain level. It estimates the global risk associated with a process unit
and classifies the units according to their general level of risk. FEI covers aspects
related to the intrinsic hazard of materials, the quantities handled and operating
conditions. This factor gives index value for the area which could be affected by an
accident, the damage to property within the area and the working days lost due to
accidents.
Fire and explosion index is then calculated as the product of Material Factor (MF) and
Unit Hazard Factor. Degree of hazards based on F& EI given in the following Tables 3
and Table 4 respectively.
Table 3: Degree of Hazards Based on F& EI
FEI Range Degree of Hazard
0 – 60 Light
61 – 96 Moderate
97 – 127 Intermediate
128 - 158 Heavy
159 and Above Severe
Table 4: Calculated Degree of Hazards Based for M/s. Shah Sponge & Power Ltd.

Sl. Unit Parameter Hazard F&EI Remarks

No. Potential
1. Raw materials Iron ore Light Physical Hazard
&
Products Coal Moderate Fire
Fly Ash, Bottom Moderate Dust & Toxic
Ash, Slag
Other fluxing Light Dust & Toxic
minerals

Product steel Light Physical Hazard

2. Iron making Coal reduction Intermediate Flammable and CO
in fuel gas pollution
Rotary kiln
Hot Metal Intermediate Personnel injury & fire

Burning coal Intermediate Personnel injury & fire

 Sl. Unit Parameter Hazard F&EI Remarks
No. Potential
3. Rolling Mills Hot metal Intermediate Fire
4. Fuel gas Gas leaks Intermediate Fire and CO pollution
Distribution
5. Electric Short circuit Intermediate Fire
power supply
6. Transformer Electrical Fire Light Explosion & fire
7. Steam turbine Explosion Moderate Fires in Lube oil
generator system, Short circuit in
building control room/switch
gear, cable galleries &
oil drum storage
8. Boilers Heat recovery Moderate Fire/steam explosion
boilers

9. Coal Handling Storage shed Moderate Fire or dust explosion

plant
10. Coal Storage Storage shed Moderate Spontaneous
Combustion
Mitigation Measures
Risk Mitigation measures for the proposed Expansion and new Installation activities
require adoption of best safety practice at the respective construction zones as well
as operational phase within the works boundary. In addition, the design and
engineering of the proposed facilities will take into consideration of the proposed
protection measures for air and water environmental as outlined in earlier Chapter.
Coal Handling Plant
• Coal handling unit shall be minimum 500 meters away from the residential area,
school/colleges, Historical Monuments, Religious Places, Ecological sensitive area
as well as forests area. Also from Railway line, Express ways, National Highways,
State ways and District Roads and from water bodies like River, Nala, Canal, Pond
etc.
• Coal storage unit shall provide paved approach with adequate traffic carrying
capacity.
• Compound wall with adequate height should be constructed around the coal
storage area
• The unit should have adequate water supply through pipe/ surface water before
selection of the site.
• Coal storage unit should ensure that stacking of coal in heaps does not get higher
than the compound wall of premises of unit
• Adequate dust suppression measures should be provided to prevent fugitive
emission and also risk of fire. Similar measures should be adopted for
loading/unloading operations. Coal ash should be transported in tankers, which
are covered and closed and there is no chance of spillage during transportation.
• Firefighting measures should be provided to avoid any fire and ensure that there
is no explosive or chemical reaction in storage yard.
• Coal unit should take measures to control the air pollution while loading/handling
coal. Specific measures should be under-taken to avoid fugitive emission at the
time of loading/unloading of coal by individual coal yard unit.
Induction Furnace
• Gas safety man would accompany the team and would test the atmosphere
for the presence of CO, before starting the work. If CO, concentration is found
exceeding the sage limit, the job would be undertaken using necessary safety
appliances viz., Oxygen Breathing Apparatus/Blower type Gas mask.
• Any gas cutting /welding job would be undertaken with the clearance from
Gas safety man.
Control Rooms
• Control rooms shall be blast proof and shock proof
• The building shall be located upwind of the process storage and handling facilities.
The building shall not be at a lower level than the tank farm.
• Adequate number of doors shall be provided in the control room for safe exit
• Smoke detectors system shall be provided for control rooms at suitable locations
• One hydrant (minimum) for every 45m per wall of the building shall be positioned
all around the building
Gas Explosion, Prevention & Preventive Measure
The following actions would be taken to prevent any gas explosions in case of gas
leakage.
• For works on gas lines/equipment, non-sparkling copper tools will used. If such
tools are not available, grease coated steel tools would be used.
• Electrical drill & other electrical equipment will not be used as these can give rise
to sparks.
• The gas line would be thoroughly purged with steam before undertaking the job
on the same.
• Naked lights will not be used near any de-pressurized gas main or equipment
unless the same has been thoroughly purged.
• In case of profuse leakage of gas, action would be taken for water sealing and
isolating that portion.
• The approach road to the gas line complex would be kept free from any
obstructions.
• If gas catches fire due to some leakage, it will be extinguished with plastic clay,
steam or water.
• The portion of gas main affected would be cooled down with water. The valve will
not be closed when fire is still there and the pressure in the main will be
maintained at minimum 100mm (WC).
• Gas tapping points of flow or pressure measurement will be cleaned with wooden
stick or grease coated wire.
• If lighting is necessary near gas line, portable spark, proof electrical lamps of low
voltage or explosion proof torchlight will be used for enclosed areas.
Mitigation measure for Hot Metal spillage
Any accumulation of water will be prevented in such vulnerable areas.
• In case of minor leakages, the flow of molten metal will be controlled.
• If there is major breakout, the area would be cut off and cordoned.
• Vital connections e.g. water, gas, compressed air, oxygen etc., would be cut off or
regulated as per requirement.
Electrical safety
• Adequately rated and quick response circuit breakers, aided by reliable and
selective digital or microprocessor based electromagnetic protective relays would
be incorporated in the electrical system design for the proposed activities.
• The metering and instruments would be of proper accuracy class and scale
dimensions. Fire Fighting Facilities
• All the fire extinguisher system will be controlled by the Security Department.
Safety department will consist of qualified safety manager, safety officer and
supporting staff.
• Portable fire extinguishers
• Fire Hydrant system
• Sprinkler system employed near fire prone areas
• Fire Buckets
Table 5: Details of Fire Fighting Facilities onsite
Sl. No. Name of site Type of Extinguisher
1 Cable galleries CO2& Foam type, Dry chemical powder
2 High voltage panel CO2& Foam type, Dry chemical powder
 3 Control rooms CO2& Foam type, Dry chemical powder
4 MCC rooms CO2& Foam type, Dry chemical powder
5 Pump Houses CO2& Foam type, Dry chemical powder
6 Guest houses and Dry chemical powder, foam type
offices
7 Godowns Foam type
8 Bunkers, Silo, CO2 type, N2 type, automatic sprinkler,
enclosed dust fixed spray nozzle(unless water reactive)
collector
Personal Protective Equipment (PPE)
Personal Protective equipments kept onsite are made readily available to plant
personnel. Table7.6 shows the lists of recommended Personal Protective equipments
(PPE) onsite.
Table 6: Summary of Recommended Personal Protective Equipment
According to Hazard
Workplace Hazards Suggested PPE
Eye and Flying particles, molten Safety glasses with side-shields,
face metal, gases or vapors, protective shades, etc.
protection light radiation
Head Falling objects, inadequate Plastic helmets for top and side
protection height clearance, and impact protection
overhead power cords
Hearing Noise Hearing protectors (ear plugs or ear
protection muffs)
Foot Failing or rolling objects, Safety shoes and boots for
protection points objects. Corrosive protection against moving and failing
or hot liquids objects, liquids and chemicals
Hand Hazardous materials, cuts Gloves made of rubber or synthetic
protection or lacerations, vibrations, material (Neoprene), leather, steel,
extreme temperatures insulation materials, etc.
Respiratory Dust, fogs, fumes, mists, • Facemasks with appropriate filters
protection gases, smokes, vapors for dust 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 / leg Extreme temperatures, Insulating clothing, body suits,
protection hazardous materials, aprons etc. of appropriate materials
 Workplace Hazards Suggested PPE
biological agents, cutting
and laceration
Fly Ash Fly ash handling and • For handling, dust-proof goggles
storage and rubber or PVC gloves.
• For large quantities or where
heavy contamination is likely,
wear: coveralls.
• For high dust levels, wear: a Full-
face Class P3 (Particulate) or an
Air-line respirator.
• For inhalation risk exists, wear: a
Class P1 (Particulate) respirator.

Occupational Health & Safety Onsite:

(i) Details of existing Occupational & Safety Hazards. What are the exposure levels
of above mentioned hazards and whether they are within Permissible Exposure
level (PEL). If these are not within PEL, what measures the company has
adopted to keep them within PEL so that health of the workers can be
preserved,
Occupational Health Hazards at M/s. Shah Sponge & Power Ltd, Jharkhand
M/s. Shah Sponge & Power Ltd will adopt suitable measures for the proper
occupational health safety of workers complying to OSHA standards. Permissible
Exposure Level (PEL) of various Chemical Handled onsite are listed below in Table No
6
• Dust Exposure level of shop floor workers shall be appropriately monitored.
• Check of the effectiveness of preventive and control measures on regular basis.
• Adequate supplies of potable drinking water is to be provided .Water supplied to
areas of Plant food preparation or for the purpose of personal hygiene (washing or
bathing) are according to drinking water quality standards
• Where there is potential for exposure to harmful dusts by ingestion arrangements
are to be made for clean eating areas, where workers are not exposed to the
hazardous or noxious substances
• Periodic medical hearing checks are to be performed on workers exposed to high
noise levels
• Provisions are to be made to provide OHS orientation training to all new employees
to ensure they are apprised of the basic site rules of work at / on the site and of
personal protection and preventing injury to fellow employees
 • Contractors that have the technical capability to manage the occupational health
and safety issues of their employees are to be hired, extending the application of
the hazard management activities through formal procurement agreements
• Ambulances and First aid treatment facilities are made available for any emergency
situation
Table 6: PEL level Summary as per OSHA
Chemical Name OSHA PEL Cal/OSHA PEL NIOSH REL ACGIH
Sl.N Mg/m3 8-hour TWA Up to 10- TLV
(ST) STEL hour TWA
(C) Ceiling (ST) STEL
Mg/m3 (C) Ceiling
Mg/m3
1. Coal Dust 0.9 (resp.)
2. a) Respirable 2.4Mg/m3 0.9(bituminous) bituminous or
fraction less lignite; 0.4
than 5% SiO2 1 (resp.) anthracite
(coal dust to be
b) Respirable 10/(%SO2) 0.1(bituminous) monitored for
fraction greater crystalline silica
than 5% SiO2
3. Iron oxide 10(fume) 5 (fume) 5 (dust and 5 mg/m3
fume)
4. Limestone

5. a) Total Dust 15 Mg/m3 10 Mg/m3 10 Mg/m3

b) Respirable dust 10 Mg/m3 5 Mg/m3 5 Mg/m3
fraction
6. Gypsum
a. Total Dust 15 10 Mg/m3 10 Mg/m3
Mg/m3
b. Respirable 10 5 Mg/m3 5 Mg/m3
dust fraction Mg/m3
7. Quartzite 5 2 Mg/m3 2 Mg/m3 2 Mg/m3
Mg/m3
8. Fly Ash (calcium 1 mg/m , natural
oxide, sillicates) as Wollastonite
(IHL,no asbestos
and <1%
crystalline silica
9. Carbon 55 25 ppm 35 ppm 25 ppm
Monooxide Mg/m3
Reference- OSHA/PEL exposure limit Guide
(ii) Details of exposure specific health status evaluation of worker. If the workers'
health is being evaluated by pre designed format, chest X rays, Audiometry,
Spirometry. Vision testing (Far & Near vision. color vision and any other ocular
defect) ECG, during pre-placement and periodical examinations give the details
of the same. Details regarding last month analyzed data of abovementioned
parameters as per age, sex, duration of exposure and department wise.
Workers' health shall be evaluated by pre designed format, given below for chest x
rays, Audiometry, Spirometrv, Vision testing (Far & Near vision. color vision and any
other ocular defect) ECG, during pre-placement and periodical examinations that
will give the details of the same.
Spirometry Tests
Total FVC FEV 1/
Year FEV 1 PEFR Conclusion
Manpower (litres) FVC %

Physical Examination Tests

Total Right Left Color
YEAR Pulse ECG BP Squint
Manpower Eye Eye Blindness

Investigations Tests
Total Blood ( Blood Sugar URINE
YEAR Lipid profile
Manpower CBC) (F& PP) ( R&M )

Audiometry Tests
Total Audiometry
YEAR Normal Abnormal Conclusion
Manpower done
(iii) Annual report of heath status of workers with special reference to
Occupational Health and Safety.
Annual report of health will be reviewed for M/s. Shah Sponge & Power Ltd,
manpower once the facility the proposed activity is. Operational as per above given
formats.
(iv) Plan and fund allocation to ensure the occupational health & safety of all
contract and casual workers.
Necessary required budgetary allocation will be kept for to ensure safety of all
Employees including contract & casual workers
Table 7: OHS Budget Details

Sl No. OHS Requirement OHS Budget

1. Route Maintenance of Fire Hydrant Line 2.00 Lakh Rupees
2. Installation of Heat Detectors, smoke detectors 4.00 Lak Rupees
and Maintenance
 Sl No. OHS Requirement OHS Budget
3. Maintain register of Fire Extinguisher system --
with proper numbering, location and next
refilling due date
4. Yearly Hydro test of Fire Extinguishers 5.00 Lak Rupees
5. Work Zone Monitoring (Production and Control 3.00 Lakh Rupees
Room)
6. Co2 Flooding System for MCC & Panel Rooms Oil 5.00 Lak Rupees
Cellar of Rolling Mill
7. Environment Audit (Once in Year) 2.00 Lakh Rupees)
8. Third Party EHS Audit (Once in 2 years) 2.00 Lakh Rupees
9. PPE Purchase 6.00 Lakh Rupees
10. Exhaust Ventilation Test 5.00 Lak Rupees
11. Yearly Occupational Health Monitoring of 2 Lakh Rupees
Employees and Record Maintenance
12. Training and Safety Awareness Program 2 Lakh Rupees
13. Safety week celebration Conduction and Safety 1 Lakh rupees
Slogans
14. Misc 1 Lakh Rupees
Total 40 Lakhs

DISASTER MANAGEMENT PLAN

The term “Disaster” refer to extensive damage of property and serious disruption both
inside, outside the work system and its surrounding that can be natural or human
interfered. Emergency may be caused by a number of different factors, e.g. plant
failure it will normally manifest itself in three basic forms viz fire, explosion or toxic
release and requires the assistance of emergency control services to handle mass
devastation effectively.
Objective of Disaster Management Plan
The objective of Disaster Management plan is to give a broad framed layout to tackle
emergency situation that may lead to a hazardous situation. It defines detail
organizational responsibilities, actions, reporting requirements, broad and specific key
roles and responsibilities of personal with Organisation and organisation charts. The
overall objectives of the emergency plan will be:
• Ensure safety of people, protect the environment
• To ensure localization of risk
• To minimize and reduce the effects of the accident on people and property.
• Immediate response to emergency scene with effective communication network
and organized procedures
• To obtain and mitigate early warning of emergency conditions so as to prevent
impact on personnel, assets and environment
• To prevent injuries by following proper onsite, offsite emergency plans that can
protect personnel from the hazard
Key Elements
Basis of Plan
Hazard Identification necessitates preparation and planning the prevention and
methods by which accidental failure can be tackled without much damage to life.
HAZID-HIRA and consequence analysis combines and requires planning for the
following:
• Hazards from spread of fire or release of flammable from storage and process
units
• Hazards due to formation of pressure waves due to vapour cloud explosion of
flammable gases
Emergency planning and Response procedure
The Emergency Response Plan is plan for dealing with emergencies are implemented
immediately whenever there is a fire, explosion, or release of a hazardous substance
that threatens human health or the environment. The emergency response plan is
reviewed and immediately amended whenever:
• The plan fails in an emergency
• The list of emergency contacts change
• The list of emergency equipment changes
• The facility changes in its design, construction, operation, maintenance, or other
circumstances in a way that increases the potential for fire, explosions, or release
of a hazardous substance
Incident Response Plan
It is the Frame work of addressing the emergency situation arose due to failure
scenario.
• Incident Response Plan(IRP) and Emergency Preparedness Plan
• Incident Response Team (IRT)
• Emergency Response Team (ERT)
• Crisis Management Team (CMT)
Onsite Disaster Management Plan
Disaster management plan are prepared with an aim of taking precautionary step to
control the hazard propagation, avert disaster, take action after the disaster which
limits the damage to the minimum and follow the on-site emergency planning.
Onsite Emergency Plans
The onsite emergency is an unpleasant situation that causes extensive damage to
plant personnel and surrounding area and its environment due to in operation,
maintenance, design and human error. Onsite plan will be applied in case of proposed
expansion. Following point are taken into consideration:
• To identify, assess, foresee and work out various kinds of possible hazards, their
places, potential and damaging capacity and area in case of above happenings.
• Review, revise, redesign, replace or reconstruct the process, plant, vessels and
control measures if so assessed.
• Measures to protect persons and property of processing equipments in case of all
kinds of accidents, emergencies and disasters
• To inform people and surroundings about emergency if it is likely to adversely
affect them
Disaster control Management system
Disaster Management group plays an important role in combating emergency in a
systematic manner. Schematic representation Emergency Control Management
system for M/s. Shah sponge & Power Ltd is shown in Fig. 1

Fig. 7.1: Onsite DMP - Disaster Control / Management System

Emergency Control Centre (ECC)
An Emergency Control Centre (ECC) is established from which emergency operations
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 area that offers minimal
risk being directly exposed to possible accidents. During an emergency, the Emergency
Management Staff, including the main controller will gather in the ECC. Therefore, the
ECC will be equipped with adequate communication systems in the form of telephones
and other equipment to allow unhampered organization and other nearby facility
personnel.
The ECC will provide shelter to its occupants against the most common accidents; in
addition, the ECC’s communication systems will be protected from possible shutdown.
The ECC will have its own emergency lighting arrangement and electric
communication systems operation. The ECC will always be ready for operation and
provided with the equipment and supplies necessary during the emergency such 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.
• 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 area
showing:
• 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
A team of following Essential persons shall be taking necessary action in case of
emergency. The roles and responsibilities of these personnel are defined
subsequently:
▪ Main Controller
▪ Site Incident Controller(SIC)
▪ Incident Controller (IC)
▪ Liaison Officer
▪ Communication Officer
▪ Observer
▪ In-charge (Security)
▪ In-charge (Medical)
▪ Shift In-charge (Security)
Main Controller
The Primary Controller is the employee who gives the first information about the
incident/accident. He will be responsible for:
• To inform the Security office (Main Gate), & Engineers/Sr. Engineers / Shift In‐
Charges/HOD of Section of the aforesaid Department/Section from the nearest
available telephone about the location and nature of incident.
• To assist rescue operation as well as clear obstruction, if any, in the same.
• To carry out all instructions from Incident Controller.
Site Incident controller (SIC)
The Unit Head shall have overall responsibility for the factory and its personnel. In
absence of Unit Head, Chairman OHS Committee shall assume the responsibility of
Site Controller. His duties during emergency shall be:
• To assess the magnitude of the situation and decide if employees need to be
evacuated from assembly points.
• To give necessary instructions to Liaison Officer, HOD(HR&A) regarding the help to
be obtained from outside agencies like Fire Brigade, Police and Medical
• To advise Liaison Officer to pass on necessary information about the incident to
News Media and ensure that the evidences are preserved for enquiry to be
conducted by statutory authorities.
Incident Controller(IC)
The HOD of affected department shall have overall responsibility for controlling the
incident and directing the personnel. Section In charge of the affected department
shall assume the responsibility of Incident Controller(IC) in the absence of HOD of
affected department. His duties during emergency shall be:
• To inform Communication Officer about the emergency, Control Center&
Assembly point.
• To direct all operations` within the affected area with priorities for safety of
personnel, to minimize damage to the Plant and environment and to minimize
loss of material.
• To act as Site Controller till the later arrives.
• To advise and provide information to Fire Squad, Security Officer and Local Fire
Services when they arrive.
• To ensure that all non‐essential persons are sent to the assembly point.
Liaison Officer
HOD (HR&A) shall be the Liaison officer. He shall be responsible for: ‐
• To contact Fire Brigade, Police, and Medical facilities on intimation from Site
Controller & arrange for the rescue operation.
• To ensure that the casualties receive attention.
• To inform relatives of the affected employee at the earliest.
• To arrange for additional transport if required.
• To arrange for relief of personnel & organize refreshment/catering facility, in case
the duration of emergency is prolonged.
• To issue authorized statements to news media and ensure that evidence is
preserved for enquiry to be conducted.
Incharge (Medical)
On receiving the information he will reach hospital immediately and take following
actions:
• He will keep necessary first aid medicines and artificial respiration equipment
ready.
• Inform doctors at other places to be ready, for attending serious injury, burn
cases and food poisoning
Observer
• During Mock Drill for Emergency Situations they shall be placed at different
locations in plant to note down the movement and action taken by people and
give feed back to the Site Controller.
Communication Officer
In‐Charge (Safety) shall act as Communication officer. He shall work from Control
Centre and maintain communication between relevant personnel. He shall be
responsible for:
• To apprise the site controller of the situation, based on the information received,
suggest the evacuation of personnel from assembly points, if needed.
• To arrange for suitable persons to act as runners/messengers in case of failure of
communication system.
• To carry out any other works as assigned by Site Controller/Incident Controller
In charge - Security
• The Incharge (Security) shall guide the crew, according to the condition of
emergency site, for the actions required to handle the emergency i.e. for fire
fighting, removal of debris, arresting of dust, removal of oil soaked earth etc. He
shall give instructions to Security Guards to cordon off areas as required by Incident
Controller. He shall render all help to incident controller to handle the emergency
and carry out the work as assigned to him.
• He shall be responsible for ensuring the discipline at control points and for
preventing the entry of unauthorized persons inside the affected area as well as
inside the factory during emergency.
Shift In-charge – Security
He shall be responsible for
• To arrange the necessary help as requested by Primary Controller.
• To inform Incharge (Security).
• To blow emergency siren, if instructed by the HOD (HR&A)/Incident Controller.
• To send Ambulance near accident area.
• To rush to the accident site with fire brigade along with available trained security
persons.
Automatic Fire Detection System
Unattended vulnerable premises like electrical control rooms, cable tunnels, MCC,
oil cellars, etc. will be provided with automatic fire detection and alarm systems.
Manual Call Point Systems
All major units and welfare/administrative building will be provide with manual
call points for summoning the fire fighting crew from the fire station for necessary
assistance.
Fire Station
The following equipment will be provided in the fire posts.
• Water tender
• Foam tender
• Portable pump
• Wireless set
• Hoses
• Hot line telephone
Alarm System
A hooter installed at the Security Office shall be blown alternately with high and low
pitch for 2 minutes to indicate major emergency in the plant. In such case, all non‐
essential employees are expected to gather at assembly point i.e. Company’s Main
Gate/Time Office. Signal for the clearance of emergency shall be given by blowing the
hooter continuously for one minute.
First Aid
• Fully equipped Hospital with Ambulance Van is available. Doctors and nurse are
available round the clock to handle any emergency in the plant. The Ambulance
shall be periodically checked through preventive maintenance programme .To
ensure that the system is strictly followed, In‐charge (Safety) shall cross check
randomly once in a fortnight the preparedness of Ambulance as per the check list
and counter sign
• The injured shall be shifted to nearby hospital, as per the opinion of the Medical
Officer.
• A list of First Aid boxes is available in every department as mentioned in ECC
• Medical Officer shall ensure that refilling is done on monthly basis and he shall
maintain a record of refilling.
• The names & contact numbers of trained First Aiders are provided the same is
displayed at all the prominent locations in the premises.
• In case of Injury caused due to Hazardous Chemicals, Material Safety Data Sheet
(MSDS) available with the user department / Hospital shall be referred.
Mock Drill
For reviewing and assessing the level of preparedness, In‐charge (Safety) shall conduct
Mock trials twice in a year (one in each half) simulating the covered emergencies and
will maintain records of the trials. The team of Prime & Deputy Responsible persons
will review the records and events of the emergency preparedness trials along with
the observations taken by the observer and report shall be put forward to the Site
Controller. Corrective and Preventive measures, if suggested/directed, will be initiated
and relevant records of the same are maintained. Fire drills will be exercised once in
every six months under the leadership of Incharge (Security). The records of Fire drill
will be recorded & maintained.
The findings of the mock drills shall be used for improvements in preparedness and
response. All team leaders shall be responsible for implementing the suggestions
based on mock drill findings within reasonable time frame.
Training
On a yearly basis class room training for fire fighting and mitigating measures to be
adopted to reduce environmental impact & OHS risks, will be imparted covering at
least 20% employee by the In‐charge (Safety) and In‐charge (Security). The records of
the same are maintained.
Evacuation Plan
To establish method of systematic, safe and orderly evacuation of all the occupants in
case of fire or any emergency, in the least possible time, to a safe assembly point
through nearest safe means of escape. Additionally to use available fire appliances
provided for controlling or extinguishing fire and safeguarding of human life.
• Facility staff will be notified of evacuation by one or more of the following
method(s): Verbal, Intercom, Portable Radio, Alarm, Other
• Notification to emergency services to ECC
• Staff will follow predetermined evacuation routes and assemble at designated
areas. Evacuation maps must be displayed throughout the facility.
• Individuals responsible for coordinating evacuations must confirm the process
Off-Site Emergency Planning
The off-site emergency plan is an integral part of any hazard control system. It is based
on those accidents identified by the works management, which could affect people
and the environment outside the works. Thus, the off-site plan follows logically from
the analysis that took place to provide the basis for the on-site plan and the two plans
therefore complement each other. The roles of the various parties that may be
involved in the implementation of an off-site plan are described below. The
responsibility for the off-site plan will be likely to rest either with the works
management or with the local authority. Schematic representation of various
organisation involved during emergency is shown below in Fig. 2.
Either way, the plan must identify an emergency coordinating officer who would take
overall command of the off-site activities. Consideration of evacuation may include
the following factors:
• In the case of a major fire but without explosion risk (e.g. an oil storage tank), only
houses close to the fire are likely to need evacuation
• If fire is escalating very fast it is necessary to evacuate people nearby as soon as
possible
• In acute emergency people are advised to stay indoors and shield themselves
from the fire.

Fig. 2: Various Organizations Involved During Emergency

Organization
Organizational details of command structure, warning systems, implementation
procedures, emergency control centres include name and appointments of incident
controller, site main controller, their deputies and other key personnel involved 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-fighting
equipment, 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-governmental Organizations (NGO)
NGO’s could provide a valuable source of expertise and information to support
emergency response efforts. Members of NGOs could assist response personnel by
performing specified tasks, as planned during the emergency planning process.
• 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 the risks
associated with them will be made available at respective site.
Meteorological information
There is to be arrangements for obtaining details of weather conditions prevailing at r
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 in combating
emergency situation after assessing the impact scenario in rescue phase.
Role of police
The police is to assist in controlling of the accident site, organizing evacuation and
removing of any seriously injured people to hospitals.
• Co-ordination with the transport authorities, civil defence and home guards
• 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 shall be organized to put out fires and provide assistance as required
during emergency.
Media
• The media is to have ready and continuous access to designated officials with
relevant information, as well as to other sources in order to provide essential and
accurate information to public throughout the emergency and to avoid
commotion and confusion
• Efforts are made to check the clarity and reliability of information as it becomes
available, and before it is communicated to public
• Public health authorities are consulted when issuing statements to the media
concerning health aspects of chemical accidents
• Members of the media are to facilitate response efforts by providing means for
informing the public with credible information about accidents involving
hazardous substances
Role of health care authorities
• Hospitals and doctors shall be ready to treat all type of injuries to causalities
during emergency.
• Co-ordinate the activities of Primary Health Centres and Municipal Dispensaries to
ensure required quantities of drugs and equipments
• Securing assistance of medical and paramedical personnel from nearby
hospitals/institutions
• Temporary mortuary and identification of dead bodies