Chapter-Vii Additional Studies

Proposed 125 KLPD Grain based Distillery, 25 KLPD Malt Spirit Plant and 4.
5 MW Co-generation Power Plant

At Village Chiraura, Tehsil Akbarpur, District Kanpur Dehat (U.P.)
Chapter-VII of Draft EIA / EMP Report
CHAPTER–VII
ADDITIONAL STUDIES
7.1 ADDITIONAL STUDIES

As per the EIA Notification dated 14 th September, 2006, and its subsequent amendments; the
submission of online application was done on 16 th February, 2018. The Committee had issued Terms of
Reference (ToR) vide letter no. IA-J-11011/58/2018-I(A) II (I) dated 24 th march, 2018 for the preparation
of Environmental Impact Assessment (EIA) and Environmental Management Plan (EMP).The following
additional studies were done in reference to the additional Terms of References;
A) Public Consultation
B) Risk Assessment
1.
7.2 PUBLIC CONSULTATION
Public hearing is yet to be conducted.
7.3 RISK ASSESSMENT
Industrial accident results in great personal & financial loss. Managing these accidental risks in today's
environment is the concern of every industry, because either real or perceived incidents can quickly
jeopardize the financial viability of a business. Many facilities involve various manufacturing processes
that have the potential for accidents which may be catastrophic to the plant, work force and
environment or public. The main objective of the risk assessment study is to propose a comprehensive
but simple approach to carry out risk analysis and conducting feasibility studies for planning &
management of industrial prototype hazard analysis in Indian context.
7.3.1 Hazard Identification & Risk Assessment (HIRA)

Hazard identification involves the identification and quantification of the various hazards (unsafe
condition) that exist in the plant. On the other hand, risk analysis deals with the identification and
quantification of the risk, the plant equipment and personnel are exposed to accidents resulting from
the hazards present in the plant.
Risk assessment involves the identification and assessment of risks to the population which is exposed
to as a result of hazards present. This requires an assessment of failure probability, credible accident
scenario, vulnerability of population etc. Much of this information is difficult to get or generate
consequently, the risk analysis in present case is confined to maximum credible accident studies and
safety and risk aspect related to grain based distillery, malt spirit plant and power plant.
Activities requiring assessment of risk due to occurrence of most probable instances of hazard and
accident are both onsite and off-site.
On-site
 Exposure to fugitive dust, noise, and other emissions
M/s. Rajasthan Liquors Limited 1

Proposed 125 KLPD Grain based Distillery, 25 KLPD Malt Spirit Plant and 4.5 MW Co-generation Power Plant
 Housekeeping practices requiring contact with solid and liquid wastes

 Emission/spillage etc. from storage & handling
Off-site
 Exposure to pollutants released from offsite/ storage/related activities
 Contamination due to accidental releases or normal release in combination with natural hazard
 Deposition of toxic pollutants in vegetation / other sinks and possible sudden releases due to
accidental occurrences
7.3.1.1 Identification of types of hazards in distillery & co-generation plant (HAZID)

Disaster at distillery and co-generation plant may occur due to following hazards:
 Fire electric panels, oil room and alcohol storage
 Explosion in boiler house etc.
 Electrocution
 Cleaning of barrels, which have held chemical substances
 Fall of material etc.
The potential hazardous areas and the likely accidents with the concerned area have been enlisted
below.
Table 7.1
Possible hazardous locations on site
S. Hazardous Area Likely Accident

No.
1. Boiler Area Explosion
2. Turbine room Explosion
3. Electrical rooms Fire and electrocution
4. Transformer area Fire and electrocution
5. Cable tunnel Fire and electrocution

6. Storage yard (Rice husk/coal) Fire
7. Storage tank (alcohol) Fire
8. Stack Uncontrolled air pollution due to failure of ESP
9. Lagoon storage Odor
10. HSD storage area Fire due to spillage
Fire

Fire can be observed in the boiler area, rice husk/coal storage yard, fuel spillage, electrical rooms,
transformer area etc. due to accidental failure scenario.
Explosion
Explosion may lead to release of heat energy & pressure waves. Table below shows tentative list of
damages envisaged due to different heat loads.
Electrocution
Fatal Accident due to carelessness during working hours may lead to electrocution.
Table 7.2
List of damages envisaged at various heat loads
S. Heat loads Type of Damage Intensity
No. (kW/m2) Damage to Equipment Damage to People
1. 37.5 Damage to process equipment  100% lethality in 1 min.
 1% lethality in 10 sec
2. 25.0 Minimum energy required to ignite wood 50% Lethality in 1 min. Significant injury
in 10 sec
3. 19.0 Maximum thermal radiation intensity --
allowed on thermally unprotected
equipment
4. 12.5 Minimum energy required to melt plastic 1% lethality in 1 min
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
7.3.1.2 Proposed mitigation measures

(A) Electricity hazard
 All electrical equipment is to be provided with proper earthing. Earthed electrode will be
periodically tested and maintained.
 Emergency lighting is to be available at all critical locations including the operator's room to
carry out safe shut down of the plant
 Easy accessibility of fire fighting facilities such as fire water pumps and fire alarm stations
will be considered
 All electrical equipment are to be free from carbon dust, oil deposits, and grease
 Use of approved insulated tools, rubber mats, shockproof gloves and boots, tester, fuse
tongs, discharge rod, safety belt, hand lamp, wooden or insulated ladder and not wearing
metal ring and chain.
 Flame and shock detectors and central fire announcement system for fire safety are to be
provided.

 Temperature sensitive alarm and protective relays to make alert and disconnect equipment
before overheating is to be considered
 Danger from excess current due to overload or short circuit is to be prevented by providing
fuses, circuit breakers, thermal protection
(B) Fuel storage
 Rice husk/coal handling unit/Agency will be at minimum 500 meters away from the
residential area, school/colleges, Historical Monuments, Religious Places, Ecological
sensitive area as well as forests area.
 Rice husk/coal handling unit will be located at a minimum 500 meters away from the
Railway line, Express ways, National Highways, State Highways and District Roads and from
water bodies like River, Nala, Canal, Pond etc.
 The unit will have adequate water supply through pipe/ surface water before selection of
the site. Rice husk/coal storage unit is to be ensured for stacking of Rice husk/coal in heaps.
 Adequate dust suppression measures will be provided to prevent fugitive emission and also
risk of fire. Similar measures will also be adopted for loading/unloading operations.
 Rice husk/coal ash will be transported in covered and closed vehicles/conveyors so that
there is no chance of spillage during transportation.
 Fire fighting measures will be provided to avoid any fire case
 Measures will be taken to control the air pollution during loading/handling of the Rice
husk/coal.
(C) Precautionary Measures for Falling material
 Safety helmets to be used to protect workers against falling material
 Barriers like toe boards or mesh guards is to be provided to prevent items from slipping or
being knocked off the edge of a structure
 An exclusion zone will be created beneath areas where work is taking place.
 Danger areas are to be clearly marked with suitable safety signs indicating that access is
restricted to essential personnel wearing hard hats while the work is in progress.
(D) Safety measures for storage & handling of alcohol
Handling and storage of alcohol will be done as per prescribed norms. The alcohol will be
directly fed to the storage area and no manual handling will be involved which reduce the
risk of spillage in the storage area. Following precautionary measures would be taken for
safety:
(a) Handling and storage measures
(i) Keeping away from oxidizers, heat and flames.
(ii) Care will be taken for avoidance of spillage, skin and eye contact
(iii) Well ventilation and use of approved respirator if air contamination is above acceptable
level will be promoted.

(iv) Avoidance of plastics, rubber and coatings in the storage area.

(v) Cool, dry, & ventilated storage and closed containers.
(vi) Grounding of the container and transferring of equipment to eliminate static electric sparks.
(b) First aid measures
For skin contact, eye contact, & inhalation.
(c) Fire Fighting Measures
Use of extinguishing media surrounding the fire as water, dry chemicals (BC or ABC powder), CO,
Sand, dolomite, etc.
Foam System for firefighting will be provided to control fire from the alcohol storage tank. The
foam thus produced will suppress fire by separating the fuel from the air (oxygen), and hence
avoiding the fire & explosion to occur in the tank. Foam would blanket the fuel surface
smothering the fire. The fuel will also be cooled by the water content of the foam.
The foam blanket suppresses the release of flammable vapors that can mix with the air.
Special Fire Fighting Procedures; Keeping the fire upwind, shutting down of all possible sources of
ignition, keeping of run-off water out of sewers and water sources. Avoidance of water in straight
hose stream which will scatter and spread fire. Use of spray or fog nozzles will be promoted, cool
containers will be exposed to flames with water from the side until well after the fire is out.
Hazardous Decomposition Products: gases of Carbon Monoxide (CO) & Carbon Dioxide (CO2).
(d) Accidental release measures
For spill cleanup, shutting off or removal of all possible sources of ignition, absorbance of small
quantities with paper towels and evaporate in safe place like fume hood and burning of these
towels in a safe manner, use of respiratory and/or liquid-contact protection by the clean-up
personnel will be promoted.
7.3.1.3 Need of establishing a fire fighting group
A small spark of fire may result into loss of lives, machines and the damage by fire may result in
high economic losses. This type of losses can be avoided by preventing and controlling the fire
instantly for which fire-fighting group will be established.
The fire fighting group would house and keep in readiness, the following types of equipment and
arrangements.
 CO2 extinguishers
 Dry powder chemical extinguishers
 Foam extinguishers
 80 mm. spray hoses
 Fire brigade
 Fire hydrant
 Protocol (chemical to combat oil fires).
In order to avoid fire in cable galleries, all the power and control cables of FRLS type (Fire
Resistant Low Smoke) will be used.

Inspection
Fire alarm panel (electrical) will cover the entire plant. The inspection group will periodically
inspect fire extinguishers in fire stations and machines and other places.
The groups will display emergency telephone number boards at vital points. The group will
regularly carry out general inspection for fire.
Procedure for extinguishing fire
The following steps will be taken during a fire accident in the system:
 As soon as the message is received about fire, one of the systems will be diverted to the
place of the fire accident along with a staff member.
 Simultaneously plant fire station will be informed by phone or walkie-talkie for fire brigades
and fire stations of nearby area.
 In the meanwhile, the pipe system will be operated to obtain maximum pressure on output.
In case cables are within the reach of fire, power supply will be tripped and the cables
shifted.
Fire fighting with water
Adequate and reliable arrangement is required for fighting the fire with water such as:
 Provision for fire brigade and fire hydrant.
 Arrangement of pipelines along and around all vulnerable areas.
 Provision of valves at appropriate points to enable supply of water at the required
place/area or divert the same to another direction/pipe line.
 Provision of overhead tanks which will be providing water during power failure and it would
work by the gravitational force.
Sources of water for fire fighting
The following two sources of water have been considered for firefighting:
 Overhead tank
 Raw water reservoir
Fire fighting with fire extinguishers
To deal with fire-other than carbonaceous fires, which can be dealt with by water suitable fire
extinguishers are required to do the job effectively. It is therefore necessary to keep adequate
number of extinguishers in readiness at easily approachable places. Adequate number of fire
stations would be provided.
 Further, other spray groups from the system will be diverted to the spot.
 In case of fire in the belt, belt will be cut near the burning portion to save the remaining
parts.
 After extinguishing the fire, the area will be well prepared for reuse.
 Foam System for fire fighting will be provided to control fire from the alcohol storage tank.
The foam thus produced will suppress fire by separating the fuel from the air (oxygen) and
hence avoiding the fire & explosion to occur in the tank. Foam would blanket the fuel

surface smothering the fire. The fuel will also be cooled by the water content of the foam.
 The foam blanket suppresses the release of flammable vapours that can mix with the air.
7.3.1.4 Environment Health and Safety Cell

The project will have full fledged EHS cell (Environment Health & Safety Cell). Main function of
EHS cell will be to assess the potential risks/hazards to environment, health of employees &
society and safety within the plant. Installation of fire fighting system, fire alarm, provision of
safety/protective equipment to workers and regular medical check-ups will be taken up. Also
regular monitoring of different parameters will be carried out to ensure safety of environment
and society. Trainings and mock drills will be carried out in regular intervals for workers to ensure
the safety in case of any accident or natural hazard.
7.3.1.5 Emergency Planning & Procedure

7.3.1.5.1 Emergency Control Center
Emergency Control Centre (ECC) is a cell from which emergency operations are directed and
coordinated. This centre activates as soon as on-site emergency is declared.
General Description of ECC
The ECC will be located in an area that offers minimal risk being directly exposed to possible
accidents.
During an emergency, the Emergency Management Staff, including the site controller shall gather
in the ECC. Therefore, the ECC shall be equipped with adequate communication systems in the
form of telephones and other equipment to allow unhampered organizations and other nearby
facility personnel.
The ECC provides shelter to its occupants against the most common accidents; in addition, the
ECC's communication systems are protected from possible shutdown. The ECC will have its own
emergency lighting arrangement and electric communication system operation.
Only a limited and prearranged number of people are admitted to the ECC, when in use. This
eliminates unnecessary interference and reduces confusion.
The ECC will be always ready for operation and provided with the equipment and supplies
necessary during the emergency such as:
 Updated copies of the On-site Disaster Management Plan.
 Emergency telephone numbers.
 The names, phone number, and address of external agencies, response organizations and
neighbouring facilities.
 The adequate number of telephone (more than two).
 Emergency lights, clocks, personal protective equipment.
 List of fire extinguishers with their type no. and location, capacity, etc.
 Safety helmets - list of quantity & location.

 Status boards/message board.

 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.
 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 & layout of Hydrant lines.
Figure 7.1: Emergency Team

7.3.1.5.2 Emergency planning for disaster due to fire

Cable rooms, transformer unit, auxiliary transformers, oil tanks, etc. within the plant are the likely
areas for which disaster management plan is to be made to deal with any eventuality of fire.
Stores, workshop, canteen and administrative building will be included.
7.3.2 Disaster management plan

Definition
A major emergency in an activity/project is one which has the potential to cause serious injury or
loss of life. It may cause extensive damage to property and serious disruption both inside and
outside the activity/project. It would normally require the assistance of emergency services to
handle it effectively.
Scope
An important element of mitigation risk is planning for emergency, i.e. identifying accident
possibility, assessing the consequences of such accidents and deciding on the emergency
procedures, both on site and off site that would need to be implemented in the event of an
emergency.
Objective
The overall objectives of the emergency plan will be:
 To localize the emergency and, eliminate it; and
 To minimize the effects of the accident on people and property.
Elimination will require prompt action by operations and work emergency staff using, for example,
fire-fighting equipment, water sprays etc.
Minimizing the effects may include rescue, first aid, evacuation, rehabilitation and giving
information promptly to people living nearby.
7.3.2.1 Phases of disaster

There are various phases of disaster including pre and post management of hazardous event that
may or has occurred.
Warning Phase
Emergencies/disasters are generally preceded by warnings during which preventive measures may
be initiated. For example uncontrollable build-up of pressure in process equipment, weather
forecast give warning about formation of vapor cloud, equipment failure etc.
Period of Impact Phase
This is the phase when emergency /disaster actually strike and preventive measures may hardly be
taken. However, control measures to minimize the effects may be taken through a well-planned
and ready-to-act disaster management plan already prepared by organization. The duration may
be from seconds to days.
Rescue Phase

This is the phase when impact is almost over and efforts are concentrated on rescue and relief
measures.
Relief Phase
In this phase, apart from organization and relief measures internally, depending on severity of the
disaster, external help are also to be summoned to provide relief measures (like evacuations to a
safe place and providing medical help, food clothing etc.). This phase will continue till normalcy is
restored.
Rehabilitation Phase
This is the final and longest phase. During which measures required to put the situation back to
normal as far as possible are taken. Checking the systems, estimating the damages, repair of
equipment and putting them again into service are taken up. Help from revenue/insurance
authorities need to be obtained to assess the damage, quantum of compensation to be paid etc.
7.3.2.2 Proposed On-Site Emergency Plan

The onsite emergency is an unpleasant situation that causes extensive damage to plant personnel
and surrounding area and its environment due to operation, maintenance, design and human
error. Onsite plan will be applied in case of proposed project. Following points will be 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 equipment 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.
7.3.2.3 Disaster control management system

Disaster Management group plays an important role in combating emergency in a systematic
manner. Schematic representation for Emergency Control Management system is shown in figure
below.

Figure 7.2: Onsite DMP - Disaster Control / Management System

7.3.2.4 Control Room Facility
Following are the facilities to be provided at the control room to tackle the emergency failure
scenarios:
 Fire Detection System is to be installed in the control room
 VHF base station with a range of 25 km and VHF handsets of range 5 km is to be installed for
ready communication in emergency
 Public address System (PAS) is to be installed to ease the communication to various corners
of the site
 The duties and responsibilities of different co-ordinators of Onsite Disaster Management Plan
are to be displayed in the Control Room.
Alarm System
A siren shall be provided under the control of Security office in the plant premises to give
warning. In case of emergencies this will be used on the instructions to shift in charge that is
positioned round the clock. The warning signal for emergency shall be as follows:
 Emergency Siren: Waxing and waning sound for 3 minutes.
 All clear signal: Continuous siren for one minute.
Communication
Walkies & talkies shall be located at strategic locations; internal telephone system EPBX with
external P&T telephones would be provided.
Fire Protection System
Fire Fighting System
The fire protection system for the unit is to provide for early detection, alarm, containment and
suppression of fires. The fire detection and protection system has been planned to meet the

above objective an all-statutory and insurance requirement of Tariff Advisory Committee (TAC) of
India. The complete fire protection system will comprise of the following.
Fire Fighting Facility: Available in existing unit and will be maintained in future.
System description of fire fighting system
The entire fire safety installation shall be compliant with the most stringent codes / standard for
the entire complex to ensure the highest safety standard and uniformity of system. Further,
before property is operational, the fire protection shall be fully operated and tested under
simulated conditions to demonstrate compliance with the most stringent standards, codes and
guidelines.
A) Fire pumping system
The fire pumping system shall comprise of independent electrical pumps for hydrant and sprinkler
system, diesel engine driven pump & jockey pump for hydrant & sprinkler system.
Electrical pump shall provide adequate flow for catering requirement of hydrant system. Diesel
engine driven fire pumps shall be provided for ensuring operation & performance of the system in
case of total electrical power failure. Jockey pumps shall compensate for pressure drop and line
leakage in the hydrant and sprinkler installation. Provision of PRS/ orifice plate shall be made in
sprinkler riser to restrict pressure on sprinkler system.
Individual suction lines shall be drawn from the fire reserve tanks at the basement level and
connected to independent fire suction header. The electric fire pumps, diesel engine driven fire
pumps and the jockey pumps shall all draw from this suction header.
Delivery lines from various pumps shall also be connected to a common header in order to ensure
that maximum standby capacity is available. The sprinkler pump shall be isolated from the main
discharge header by a non return valve so that the hydrant pump can also act as standby for the
sprinkler system. The ring main shall remain pressurized at all times and Jockey pumps shall make
up minor line losses. Automation required to make the system fully functional shall be provided.
B) Fire hydrant system
Internal and external standpipe fire hydrant system shall be provided with landing valve, hose
reel, first aid hose reels, complete with instantaneous pattern short gunmetal pipe in the
Complex.
The internal diameter of inlet connection shall be at least 80 mm. The outlet shall be of instant
spring lock type gunmetal ferrule coupling of 63 mm dia. for connecting to hose pipe. Provision of
flow switch on riser shall be made for effective zone monitoring. The flow switch shall be wired to
FAP and shall indicate water flow on hydrant of the identified zone.
Recessed cupboard/ fire hydrant cabinet shall be strategically located for firefighting
requirement. Location of cabinets shall be accessed as per compartmentation plan in consultation
with the Architect. Provision of fire man's axe shall be made for internal hydrant.

External hydrant shall be located within 2 m to 15 m from the building to be protected such that
they are accessible and may not be damaged by vehicle movement. A spacing of about 45-50 m
between hydrants for the building shall be adopted. Details of fire hydrant system are as follows:
Piping: Mild Steel pipes (heavy class) as per IS: 1239 shall be provided throughout the complex.
Pipes buried below ground shall be suitably lagged with 2 layers of 400 micron polythene sheet
over 2 coats of bitumen.
External Hydrants: External hydrants shall be provided all around the Complex. The hydrants shall
be controlled by a cast iron sluice valve or butterfly valve. Hydrants shall have instantaneous type
63 mm diameter outlets. The hydrants shall be double outlet with CI duck foot bend and flanged
riser or required height to bring the hydrant to correct level above ground.
 For each external fire hydrant two numbers of 63 mm dia. 15 m long controlled percolation
hose pipe with gunmetal male and female instantaneous type couplings machine wound
with GI wire, gunmetal branch pipe with nozzle shall be provided.
 Each external hydrant hose cabinet shall be provided with a drain in the bottom plate.
 Each hose cabinet shall be conspicuously painted with the letters "FIRE HOSE".
 Internal Hydrants: Internal hydrant shall be provided on each landing and other locations as
required by NBC with double headed gunmetal landing valve with 100 mm diameter inlet,
with shut off valves having cast iron wheels. Landing valve shall have flanged inlet and
instantaneous type outlets.
 Instantaneous outlets for fire hydrants shall be standard pattern and suitable for fire hoses.
 For each internal fire hydrant station two numbers of 63 mm dia. 15 m long rubberized
fabric lined hose pipes with gunmetal male and female instantaneous type coupling
machine would be with GI wire, fire hose reel, gunmetal branch pipe with nozzle shall be
provided.
 Standard fire hose reels of 20mm diameter high pressure rubber hose 36.5 m long with
gunmetal nozzle, all mounted on a circular hose reel of heavy duty mild steel construction
having cast iron brackets shall be provided. Hose reel shall be connected directly to the wet
riser with an isolating valve. Hose reel shall be mounted vertically.
 Each internal hydrant hose cabinet shall be provided with a drain in the bottom plate. The
drain point shall be led away to the nearest general drain.
 Each internal hydrant hose cabinet containing items as above shall also be provided with a
nozzle spanner and a Fireman's Axe. The cabinet shall be recessed in the wall.
 Each hose cabinet shall be conspicuously painted with the letters "FIRE HOSE ".
Hose Reel: Hose reel shall be heavy, 20 mm dia, length shall be 36.5 meter long fitted with gun
metal chromium plated nozzle, mild steel pressed reel drum which can swing up to 170 degree
with wall brackets of cast iron finished with red and black enamel complete.
Sprinkler system

Elaborate automatic sprinkler system shall be provided. The system shall be suitably zoned for its
optimum functional performance.
The sprinkler system shall be provided with control valves, flow and tamper switches at suitable
location and shall be connected to control module of the fire alarm system for its monitoring and
annunciation in case of activation.
Sprinkler type along with its quartzite bulbs rating shall be selected based on the requirement of
the space and shall be specified accordingly. Inspector's test valve assembly with sight glass shall
be provided at remote end with discharge pipe to drain outlet / pipe.
Fire extinguishers
Portable fire extinguishers of water (gas pressure), Carbon di-oxide, foam type, Dry chemical
powder and FM-200 or clean agent type shall be provided as first aid fire extinguishing appliances.
These extinguishers shall be suitably installed in the entire areas as per IS: 2190.
The appliances shall be so installed over the entire sections, that a person is not required to travel
more than 15 m to reach the nearest extinguisher. These shall be placed or hanged on wall in a
group on several suitable places.
Fire pump
The fire pump shall be horizontally mounted, variable speed type. It shall have a capacity to
deliver and developing adequate head so as to ensure a minimum pressure at the highest and the
farthest outlet. The pump shall be capable of giving a discharge of not less than 150 per cent of
the rated discharge, at a head of not less than 65 per cent of the rated head. The shut off head
shall be within 120 per cent of the rated head.
The pump casing shall be of cast iron and parts like impeller, shaft sleeve, wearing ring etc. shall
be of non-corrosive metal like bronze/brass/gun metal. The shaft shall be of stainless steel.
Provision of mechanical seal shall also be made.
Bearings of the pump shall be effectively sealed to prevent loss of lubricant or entry of dust or
water. The pump shall be provided with a plate indicating the suction lift, delivery head,
discharge, speed and number of stages. The pump casing shall be designed to withstand 1.5 times
the working pressure.
Foam System for Fire Fighting
Aqueous Film-Forming Foams (AFFF) based on combinations of fluoro-chemical surfactants,
hydrocarbon surfactants, and solvents will be used as foam agent. These agents require a very
low energy input to produce a high quality fire fighting foam.
Foam concentrate will be stored in a bladder tank system. In AFFF systems a bladder tank
containing a nylon reinforced elastomeric bladder is used to store the foam concentrate. System
water pressure is used to squeeze the bladder providing fire fighting foam concentrate, at the
same pressure, to the proportioned.
An aqueous film will be formed on the surface of the alcohol by the foam solution as it drains
from the foam blanket.

This film is very fluid and floats on the surface of most alcohol. This gives the AFFF unequaled
speed in controlling the spill fire.
First Aid
A first aid centre with adequate facilities shall be provided. It shall be maintained round the clock
by a compounder cum dresser and a doctor. An Ambulance shall also be provided at site to carry
affected people to hospital.
Security
The security requirements of the company premises shall be taken care of by CSO assisted by a
Fire In charge. The team, apart from the normal security functions will manage the role required
during a disaster management operation as a part of the crisis control team.
Safety
The safety wing led by a Safety Manager will meet the requirement of emergencies round the
clock. The required safety appliances shall be distributed at different locations of the plant to
meet any eventualities. Poster/placards reflecting safety awareness will be placed at different
locations in the plant area.
Evacuation Procedure
As the major hazard is only due to fire, which has more or less localized impact so no mass
evacuation, procedures are required. Evacuation would involve only the people working very
close to the fire area.
Personal Protective Equipment (PPE)
This equipment is used mainly for three reasons; to protect personnel from a hazard while
performing rescue/accident control operations, to do maintenance and repair work under
hazardous conditions, and for escape purposes. The list of Personal Protective Equipment
provided at the facility and their locations shall be available in ECC.
Effective command and control accomplish these functions necessitates personal trained in this
On-site Disaster Management Plan with adequate facilities and equipment and equipment to carry
out their duties and functions. These organizations and the facilities required to support their
response are summarized in the following subsections.
Personal protective equipment play a vital role in overcoming major disastrous situation saving
life during onsite emergency. List of recommended Personal Protective equipment (PPE) is given
below.
Table 7.3
Summary of recommended personal protective equipment according to hazard onsite
Objective Workplace Hazards Suggested PPE
Eye and face Flying particles, molten metal, Safety glasses with side-shields, protective
protection liquid chemicals, gases or shades, etc.
vapors, light radiation
Head Falling objects, inadequate Plastic helmets with top and side impact

protection height clearance, and overhead protection

power cords
Hearing Noise, ultra-sound Hearing protectors (ear plugs or ear muffs)
protection
Foot protection Falling or rolling objects, Safety shoes and boots for protection against
points objects. Corrosive moving and falling objects, liquids and
or hot liquids chemicals
Hand protection Hazardous materials, cuts Gloves made of rubber or synthetic material
or lacerations, vibrations, (Neoprene), leather, steel, insulation
extreme temperatures materials, etc.
Respiratory Dust, fogs, fumes, mists, Facemasks with appropriate filters for dust
protection gases, smokes, vapors 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, aprons etc. of
protection hazardous materials, appropriate materials
biological agents, cutting and
laceration
Contact with Fuel oil storage and fuel Handling Canister type gas mask. PVC or Rubber.
HSD Goggles giving complete protection to eyes.
Eye wash fountain with safety
Fly Ash Fly ash handling and storage Wear dust-proof goggles and rubber or PVC
gloves.
When using large quantities or where heavy
contamination is likely, wear: coveralls.
At high dust levels, wear: a Full-face Class P3
(Particulate) or an Air-line respirator where an
inhalation risk exists, wear: a Class P1
(Particulate) respirator.
Mock Drill
As per the Industrial Major Accident Hazard Rules,
 Mock drills of the on-site emergency plan will be conducted every month.
 A detailed report of the mock drill conducted will be made immediately available to all the
concerned authority
 Also, Major Fire and Minor Fire mock drills will be conducted once in three months and one month
respectively.
Training

On job training to the engineers on various stages of risk analysis and preparedness during emergency to
reflect in the operation of terminal, especially from the safety stand point. The fire team belonging to the
fire fighting department is to be intensively trained for the use of all equipment and in various fire
fighting methods for handling different types of fires.
Details of Training facilities for:

Safety Monthly
Fire fighting Monthly
Occupational health & safety Monthly
7.3.2.5 Procedure for Testing & Updating the Plan
Simulated emergency preparedness exercises and mock fire fighting exercises including mutual aid
scheme resources and in conservation with district emergency authority to be carried out time to time.
Disclosure of Information to Worker & Public Awareness System in Existence & Anticipated
 Safety awareness among workers by conserving various training programs and seminars,
competition, slogans etc.
 Practical exercise.
 Distribution and practices of safety Instructions.
 Safety Quiz contests.
 Display of Safety Posters & Safety Slogans.
 Developing Safety Instructions for every Job and ensuring these instructions/booklets or manuals
by the workers.
7.3.2.6 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 organization involved during emergency is shown below in Figure &
Table below shows communication nos. during offsite emergency.
Table 7.4
Local Statutory Government bodies PLEASE PROVIDE CONTACT NUMBERS OF GOVT. BODIES
S. Name of Govt. Agency Phone Nos.
No.
1 District collector/ Magistrate
2 Sub Divisional Officer / Magistrate
3 Factory Inspector of the area
4 PCB Head Quarters

5 DCP Traffic (HQ/Control room)/ SP

7 Addnl. Commissioner of Police/ CO
8 Fire Brigade
9 Police Station
10 Director Ind. Safety & Health/ DDF
11 DGFASLI (Directorate General Factory Advice Service and
Labour Institutes),/ DDF
12 Dy. Chief Controller of Explosive/ ADM(E)
13 Govt Hospital(nearest)
14 Civil Surgeon
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.
Figure 7.3: Various organizations involved during emergency

Organization
Organizational details of command structure, warning systems, implementation procedures,
emergency control centers 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 are to be made available at respective site.
Meteorological information
There are arrangements for obtaining details of weather conditions prevailing at or before the time of
accident and weather forecast updates.
Humanitarian Arrangements
Transport, evacuation centers, 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, Samiti, municipalities can help in combating emergency
situation after assessing the impact scenario in rescue phase.
Role of police
Police are 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 defense 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 is to 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 will be made to check the clarity and reliability of information as it becomes available,
and before it is communicated to public.
 Public health authorities will be 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 must be ready to treat all type of injuries to causalities during emergency.
 Co-ordinate the activities of Primary Health Centers and Municipal Dispensaries to ensure
required quantities of drugs and equipment
 Securing assistance of medical and paramedical personnel from nearby hospitals/institutions
 Temporary mortuary and identification of dead bodies.
7.4 Occupational health & safety hazards and their management

To control and minimize the risks at workplace, the company has implemented health, safety and
environment policy with the following objectives:
 To prevent hazards
 To provide safe and healthy environment to all the employees.
The company, therefore, has adopted the policy set below for the purpose of creating and maintaining
safe and healthy environment.
7.4.1 Occupational Health and Safety Hazards

Following Occupational Health and safety Hazards will be there in the proposed distillery unit:
 Dust
 Noise
 Heat stress
 Electrical Hazards
 Fire and Explosion
 Other Hazards
(1) Dust
A) Risks involved
 Presence of rice husk/coal dust may cause respiratory disorders.
B) Mitigation
 Implementation of adequate dust control systems and good housekeeping will be done.

(2) Noise
A) Risks involved
 Hearing impairment, hypertension, increase pulse rate
 Annoyance, Tinnitus, Sleep disturbances
C) Management measures
 Proper maintenance of machineries
 Installation of compressors and turbine in closed buildings
 Regular monitoring of noise level
 Display of noise level with permission level
 Display instruction to use of PPEs at high noise level area
 Periodic health checkup for audiometry for the person working in high noise area.
(3) Heat stress
A) Risks involved
 Co-gen plants operate at high temperatures up to 800⁰ C
B) Management Measures
 Schedule hot jobs for the cooler part of the day
 Monitor workers who are at risk of heat stress
 Provide rest periods with water breaks
 Use of personal protective equipment
(4) Electrical Hazards
A) Risks involved
 Electric shock, electric burns, fires and explosions
 Persons falling from height, dropping of tools and object
B) Causes of hazards
 Insulation failure, equipment failure, poor maintenance.
 Wrong work methods, substandard material and workmanship
 Unauthorized personal & lack of training and knowledge, etc.
C) Management Measures
 Proper earthing will be done as per IS 3043
 Low Voltage Supply will be ensured
 Isolating Transformers
 Double Insulated Tools
 Over Load Protection
 Protection Against Leakages (G.F.C.I.)
 Flame- Proof Equipment
 Lightning Protection
 Protection against Static Electricity and safe use of ladders and scaffolds
(5) Fire and Explosion

A) Risks involved
Fire catching in store, go down, conveyors, cable tunnel, oil storage area, fuel storage yard,
transformers and HT/LT substation etc.
 Suitable fire extinguisher, fire hydrant system and fire buckets. Fire tender will be kept ready at
plant main gate.
 Oil and flammable gases storage area will be fenced and declared as Fire Hazardous Area-No
Smoking Area”
 Permit and safety instruction to use welding / gas cutting in the area of oil storage, fuel storage.
 Predictive interlock in transformers to give alarm and trip the system
 Adequate height of brick walls for separation of all transformers, soak pits for storage of oil
leakages from transformers
(6) Other Hazards
A) Risks involved
 Silo/tank and building collapse
 Slipped and fall from working at height
 Failure of lifting tools, tackles and pressure vessel
 Occupational injuries
 Hit by moving, flying or falling object
 Structural soundness of buildings
 Permit to work at height with work instruction to use safety belts etc.
 Testing of all lifting tools, tackles and pressure vessel.
 Safe working pressure will be maintained in air receiver.
 Safe working load for cranes and ropes etc.
 Good housekeeping & speed limit of 20km/hr in plant area.
 Display of emergency number at all suitable location.
 Fire tender, ambulance and emergency staff ready at the plant main gate at all the time.
 First aid kits will be kept at the site and training provided.
 Use of mobile while driving, alcohol, smoking etc. will be banned in proposed distillery area.
 Proper illumination in office (250 to 300 LUX), plant area (100 to 150 LUX) and road area (20 to
30 LUX).
7.4.2 Occupational Health Surveillance

In distillery plant, the occupational health surveillance of the employee will be done on a regular basis
and record of the same will be maintained as per the Factories Act. The occupational health
surveillance program will include lung function; sputum analysis and audiometric analysis on regular

basis to observe any contraction due to exposure to dust and noise and corrective measures will be
taken accordingly.
Vocational training programme will also be conducted. Under vocational training the workers will be
given training related to all safety and health aspects pertaining to their vocation and thereafter every
quarter special training courses/ awareness programme for Malaria eradication, HIV and health effects
on exposure to dust, heat, noise, chemicals will be organized for employed person.
Periodical medical camps with specialized doctors of various disciplines will also provide the
specialized medical assistance to employees as well as neighbouring communities.
A. Pre placement and periodical health status
Pre / Post-employment checkup will be carried out and following tests will be conducted:
 BMI (Body Mass Index)
 Chest x ray PA view
 Vision testing (Far & Near vision, color vision and any other ocular defect)
 ECG
 Haemogram (examination of the blood)
 Blood Pressure & Blood Sugar Fasting
 Serum Cholesterol
 Renal Function Test (Blood Urea, Serum Creatinine)
 Liver Function Test (S. Bilirubin, Alk. Phosphatase, SGOT and SGPT)
 Urine (Routine and Microscopic)
 Complete physical examination
 Post-employment occupational health check-up such as lung function, audiometry, CBC, Blood
Sugar, Lipid Profile etc.
 Medical records of each employee will be maintained separately and will be updated as per
finding during monitoring.
 Medical records of the employee at the end of his / her term will be updated.
B. Frequency of Medical Examination
 Once in a year
C. Personal protective devices and measures
 Industrial Safety helmets, Crash helmets
 Face shield
 Goggles
 Safety Shoes & Rubber Gumboots: Safety shoes are mandatory to be worn by all the employees
and rubber gumboots will be provided to person who handles sulphuric acid. Full suit having hand-
gloves, goggles, helmet and aprons will be provided.
 Face Shield Helmet: The people deputed for welding work will be provided with face shield
helmet.
 Ear muffs and Ear Plugs

 Full body Safety harness

 Leather hand gloves, Asbestos hand gloves, Electrical hand gloves, Heat Resistive hand gloves,
Chemical hand gloves and Cut resistance hand gloves
 Safety net, Barricading net
 Protective clothing, Dangari etc.
 Safety belt / line man's safety belt
7.4.3 Implementation of OHS standards as per OHSAS/USEPA
The overall objective of the company is to provide a system that is capable of delivering healthy and
safe workplace. Following measures will be adopted for implementation of OHS standards.
 Well-equipped Occupational Health Centre with adequate paramedical staff
 Routine and special investigation related to occupational health
 Health surveillance and maintenance of health record
 Rules and procedure for effective implementation of Safety Health and Environment policy and
made to know all employees
 Round the clock ambulance facility
 Sufficient number of first aid boxes
 Formulation of OHS implementation team/ cell
 Risk assessment of each and every activity
 Implementation of OHS management program
 Displaying the safety and health policy and instructions at various locations
 Display of safe operating procedure (SOP) at various locations
 Job safety analysis
 Carry out daily plant safety inspection by internal safety department
 Investigation of fatal, serious accidents
 Investigation of reports of occupational diseases
 Monthly safety meeting of all employees & workers to discuss last month accident if any, reason
and corrective measures taken.
 Organize safety training, seminars for safe working and safe vehicle and traffic movement within
the plant premises and regular training for safe driving outside the plant premises
 Prepare annual reports of accidents and occupational diseases. Preparation and updating of
Onsite Emergency Plan and liaison with external agencies and authorities
 Ensure use of PPEs according to the job like helmet, safety shoes, goggle, dust mask, ear plug
and hand gloves etc.
 Establishment of Occupational Health Centre for pre and periodic medical examination of
workers and staff to detect any onset of occupational disease and corrective measures
 Display Material Safety Data Sheet (MSDS) for use of every hazardous substance
 Implement the recommendations of HAZOP (Hazard and operability study) for examination of
problems in existing process / operation that may represent risks to personnel or equipment

 Periodic safety audits both internal and external, review and implementation of
recommendations
7.4.4 Safety Committee

A safety committee will be formed and manned by equal participation from management and workers
with the following functions:
a) Accident prevention and control including ensuring the use of safety appliances.
b) Publicity, propaganda, education and training.
c) Assisting and cooperating with the management in achieving the aims and objectives outlined in
the “Health and Safety Policy” of the occupier.
d) Carrying out health and safety surveys for identifying unsafe working condition/practices, which
causes accident.
7.4.5 Medical Facilities

The company will be provided with occupational health center functioning round the clock. Qualified
doctor for 24 Hrs. Availability of pharmacist and ambulance will be there at site to render the medical
assistance. Tie up arrangements will be there with nearest hospital and nursing home for the plant.
First aid boxes will be kept in 15 identified locations for emergency.
Apart from these, specialists will visit plant to render consultation. Camps for immunization, family
planning, blood donation and free medical checkup programs will be organized on regular basis for
employees.
7.4.6 Investigation Facility
Full-fledged pathological laboratory, X-ray machine with routine and specialized investigation facilities
will be made available at the plant.
7.4.7 Ambulance Services
The hospital will have an ambulance to bring the patients to hospital in case of emergency.
7.4.8 First Aid Boxes
First aid boxes will be provided at prominent places with following items:
 Small size sterilized dressing.
 Medium size sterilized dressing.
 Large size sterilized dressing.
 Burnol Ointment.
 Packets of sterilized cotton wool.
 Bottle (120 ml) of cetramide solution (1%) of suitable antiseptic solution.
 Mercurochrome solution (in 2% water).
 Scissors.
 Adhesive plaster (2 cm x 1 m).
 Sterilized eye pads in separate sealed packets.

 Aspirin tablets.
 Potassium permanganate crystals.
First aid boxes will be kept in every department for emergency. First aid training will be organized for
the employees.
7.4.9 Plan and Fund allocation for Occupational and Safety Hazards
Plan and fund allocation to ensure the occupational health and safety of all contracts and sub-contract
workers is given in table below.
Table – 7.5
Proposed fund allocation for occupational and safety hazards PLEASE PROVIDE BUDGET FOR OHS
S. Description Amount (Rs. In lacs per annum)
No.
1. Doctor's Retainer Fee(including staff)
2. Medicine Expenses
3. Health Checkup Exp.
4. Ambulance Expenditure
Total Amount in (Rs.)
7.5 Conclusion
It is concluded that there will be no major risk involved due to proposed project. Proper precautionary
measures will be taken to minimize risks. Personal Protective Equipment (PPEs) will help to minimize
the health hazards and accidental casualties.

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Proposed 125 KLPD Grain based Distillery, 25 KLPD Malt Spirit Plant and 4.

5 MW Co-generation Power Plant

7.1 ADDITIONAL STUDIES

7.3.1 Hazard Identification & Risk Assessment (HIRA)

M/s. Rajasthan Liquors Limited 1

 Housekeeping practices requiring contact with solid and liquid wastes

7.3.1.1 Identification of types of hazards in distillery & co-generation plant (HAZID)

S. Hazardous Area Likely Accident

2. Turbine room Explosion

3. Electrical rooms Fire and electrocution

4. Transformer area Fire and electrocution

5. Cable tunnel Fire and electrocution

8. Stack Uncontrolled air pollution due to failure of ESP

9. Lagoon storage Odor

10. HSD storage area Fire due to spillage

M/s. Rajasthan Liquors Limited 2

7.3.1.2 Proposed mitigation measures

M/s. Rajasthan Liquors Limited 3

M/s. Rajasthan Liquors Limited 4

(iv) Avoidance of plastics, rubber and coatings in the storage area.

M/s. Rajasthan Liquors Limited 5

M/s. Rajasthan Liquors Limited 6

7.3.1.4 Environment Health and Safety Cell

7.3.1.5 Emergency Planning & Procedure

M/s. Rajasthan Liquors Limited 7

 Status boards/message board.

Figure 7.1: Emergency Team

M/s. Rajasthan Liquors Limited 8

7.3.1.5.2 Emergency planning for disaster due to fire

7.3.2 Disaster management plan

7.3.2.1 Phases of disaster

M/s. Rajasthan Liquors Limited 9

7.3.2.2 Proposed On-Site Emergency Plan

7.3.2.3 Disaster control management system

M/s. Rajasthan Liquors Limited 10

Figure 7.2: Onsite DMP - Disaster Control / Management System

M/s. Rajasthan Liquors Limited 11

M/s. Rajasthan Liquors Limited 12

M/s. Rajasthan Liquors Limited 13

M/s. Rajasthan Liquors Limited 14

M/s. Rajasthan Liquors Limited 15

protection height clearance, and overhead protection

M/s. Rajasthan Liquors Limited 16

Details of Training facilities for:

7.3.2.6 Off-Site Emergency Planning

M/s. Rajasthan Liquors Limited 17

5 DCP Traffic (HQ/Control room)/ SP

Figure 7.3: Various organizations involved during emergency

M/s. Rajasthan Liquors Limited 18

Details of Voluntary organizations, telephone numbers nearby of hospitals, Emergency helpline,

M/s. Rajasthan Liquors Limited 19

7.4 Occupational health & safety hazards and their management

7.4.1 Occupational Health and Safety Hazards

M/s. Rajasthan Liquors Limited 20

M/s. Rajasthan Liquors Limited 21

7.4.2 Occupational Health Surveillance

M/s. Rajasthan Liquors Limited 22

M/s. Rajasthan Liquors Limited 23

 Full body Safety harness