Hazard Area Classification - Report Model

Expansion of Grain based Distillery from 165 KLPD to 465 KLPD by installation of new 300 KLPD Ethanol Plant
& Co-Generation Power Plant from

3.3 to 13.5 MW
At Village Jundla, Tehsil Karnal, District Karnal, Haryana
Risk Assessment Report
RISK ASSESSMENT REPORT
1.0 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.
1.1 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, due to accidents resulting from the hazards present
in the plant.
Risk assessment involves the identification and assessment of risks to the population exposed to 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
expansion and installation project.
Activities requiring assessment of risk due to occurrence of most probable instances of hazard and accident
are both onsite and off-site.
On-site- An incident which takes place in an industry and its effect are confined to the factory premises
involving only the people working in the factory.
 Exposure to fugitive dust, noise, and other emissions
 Housekeeping practices requiring contact with solid and liquid wastes
 Alcohol leakage/ spillage through pipeline during pumping & subsequent fire
Off-site- If an incident takes place in an industry and its effects are felt outside the Factory premises, the
situation thus generated is called an offsite Emergency.
 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.
In view of the hazards involved in handling and storage of hazardous chemicals and processes “On Site
Emergency Plan” has been prepared. It gives a clear organization structure, including outside agencies and
elaborates the duties to be performed by each individual when situation demands. The plan enumerates the
actions required to be taken by various personal working at different work station in the plant. Particular
Haryana Liquors Pvt. Ltd.

Expansion of Grain based Distillery from 165 KLPD to 465 KLPD by installation of new 300 KLPD Ethanol Plant & Co-Generation Power Plant from
3.3 to 13.5 MW
emphasis is given to eight most vital areas of disaster planning like Organization responsibilities, procedure,
training, mutual aid, communication, transportation and public relations.
1.1.1 Identification of Types of Hazards in Distillery & Co-generation Power Plant (HAZID)
The following types of hazards are identified at the company.
Table: 1
Hazard Identification
S. No. Name Description Severity Hazard

1. Transportation of raw Biomass Major Fire
material, fuel and Enzymes, yeast, nutrients, etc. Minor Exposure & inhalation
storage
Chemicals (Caustic, acids, etc.) Major Exposure to skin
2. Manufacturing Process Distillation Major Heat & Fire
3. Other Utilities Boiler, D.G Sets Major Noise, Heat, Fire & electrocution
4. Products Alcohol Major Fire
5. Other accidents Leakages from the vessels, rupture Major Exposure &Fire
of pressure vessels and storage
tanks
1.1.2 Types of Accidents Possible

Main hazard in the plant comes from handling of Class A Solvents – Ethanol
Causes of Incident Relevance for Jundla Works

Fire Very High
Loss of Containment High
Vandalism Low
Explosion Low
Loss of Process Control Very Low
Plant Modification Low
Management of Contractors Low
Causes of Incident Relevance for Jundla Works

Human Error Low
Runaway Reaction NIL
Electrocution Medium
Natural Causes
Floods High
Cyclonic Winds Low
Act of War Low
Earthquake Low
Sabotage Low
Major Injury/Illness Medium
1.1.3 Assessment of Risk along with mitigation measures

Qualitative risk assessment based on categorization of both probability and impactprovides greater insight
into the absolute risk severity. The riskimpact assessment investigates the potential effect on a project

3.3 to 13.5 MW
objective such asschedule, cost, quality, or performance, including both negative effects for threats
andpositive effects for opportunities.
Table: 2
Risk Assessment table along with mitigation measures
S. Associated Associated risk/ Risk

Activity Mitigation Measures
No. hazards health impact rating
1. Storage & Bursting of Exposure, physical H • Use of PPEs.

handling of raw storage tanks injuries • Inspection & regular monitoring
material & • Training to workers for proper handling
Chemicals
• Proper system for loading operation to
prevent any spillage.
• Spill kit for Acid and other chemicals
2. Working near Heat & Fire Physical injuries H • Firefighting facility

Distillation and burning • Provision of pressure indicators in the
column vessels.
• Use of PPEs.
• Inspection & regular monitoring
• Training to workers for proper handling
3. Fuel yard Heat & Fire Physical injuries H • Storage should be away from ignition
and burning source
• Provision of Firefighting facility
• Provision of PPEs
• First aid box
4. APCD failure Release of PM in Air pollution M • Regular monitoring & inspection shall be
ambient air done.
• The plant shall immediately shut down on
APCD failure
5. Working at Slip, trips & falls Physical injuries H • Individual alertness of the workers.
height of operators • First aid boxes shall be provided
6. Storage of Exposure, Exposure to over H • Well ventilation

Alcohol inhalation, 100 ppm may • Keeping away from heat sparks & open
ingestion & Fire cause headache, flame.
drowsiness, etc. • PPEs.
Ingestion may lead • Firefighting measures shall be readily
to depression of available.
CNS, nausea, etc.
Burn injuries
8. Release of high Explosion Risk of severe H • Regular maintenance & inspection of

pressure steam injury, damage to parts.
from boiler equipment • Proper training to the individuals
• PPEs

3.3 to 13.5 MW
S. Associated Associated risk/ Risk

Activity Mitigation Measures
No. hazards health impact rating
• First aid kit
9. Electrical Electric shock, Electrical shocks, H • Regular checking and maintenance of

maintenance short circuits in Injury or burn electrical units
work power room • PPEs
• Provision of First aid box
10. Working near High noise Noise induced M • Provision of PPEs to the workers.
Boiler, D.G. sets hearing losses
Note: H- High; M- Moderate

3.3 to 13.5 MW
Table 3
Identification of Hazard and Risk, Risk Assessment and Risk Management Measure
Hazard/ Associated risk identification Risk assessment
Adequacy of Severity Overriding Risk
Condition Risk
Activity/ measures S2= LxC Total Risk factor(LC/D Management
Scal Detectabili
Services Hazard Gap Level of S1+S2+ classificati C/Any Measure
D/ R/N N/A Likeliho Consequen e S1 Likeliho ty (D)
Existing s, if Consequen D on others) required
I R N/E od ces od(L)
any ce (C )
Mandatory use
Falling or
Distillery Minute Injury on of helmets in
slippage D NR E Helmets N 8 5 6 10 48 low -
operations injury head the plant
from stairs
premises.
Fire
Fire Major
Boiler Fire & Burning extinguishers
D NR E extinguish N burning and 9 5 10 10 69 medium -
operations explosion of skin for emergency
ers loss of life
fire
Electric Facility of
Power
shock/shor D NR E N injury Loss of life 7 6 10 10 77 Medium - onsite fire
generation
t circuit extinguishers
Burning
On site
Handling Fire of
Fire & availability of
of alcohol D NR E extinguish N property Loss of life 8 4 9 10 54 Low -
explosion Fire
& storage ers and
extinguishers
persons
Water
Burning Fire
Storage of sprinkling
of life extinguishers
coal and Fire D NR E & fire N Loss of life 7 6 9 10 71 Medium -
and and water
biomass extinguish
property sprinkling
ers
Handling Proper
Burning, Material safety
& storage labeling Major burns
Spillage D R E N rashes 8 5 8 10 58 Low - data sheet and
of and on skin
on skin proper labeling
Chemicals storage
Legend:
LC: Legal Concern, if concerning activity/associated hazard is covered under Indian OHS Legislation, DC: Domino concern, if concerning activity/associated hazard can trigger series of
accident. Any other:Any other relevant factor if applicable related to /or affecting the significance of OHS risks.
D:Direct; I- Indirect; R= Routine; NR:Non-Routine; N: Normal; AN:Abnormal; E:Emergency

3.3 to 13.5 MW
1.1.4 Safety Measures for Storage & Handling of Alcohol

The alcohol is being/will be directly fed to the storage tanks (bottling unit) mechanically and no manual
handling is being/will be involved which reduces/will reduce the risk of spillage. Following precautionary
measures would be taken for safety:
 HANDLING AND STORAGE: Keeping away from heat, sparks and open flame, care is being/will be
taken for avoidance of spillage, skin and eye contact, well ventilation, use of approved respirator if air
contamination is above acceptable level is being/will be promoted. For Storage and handling
following precautions are being/will be taken:
 Keeping away from oxidizers, heat and flames.
 Avoidance of plastics, rubber and coatings in the storage area.
 Cool, dry, & ventilated storage and closed containers.
 Grounding of the container and transferring of equipment to eliminate static electric sparks.
 Storage of acid and alkalies should be done properly as they can cause severe burns on skin.
In case of any emergency following measures are being/will be taken:
 FIRST AID MEASURES: For skin contact, eye contact, & inhalation.
 FIRE FIGHTING MEASURES:
 In plant precautions have been taken by declaring plant operating area as No Smoking Zone.
 All the Electrical installations are flame proof type in the alcohol storage area.
 Use of extinguishing media surrounding the fire as water, dry chemicals (BC or ABC powder), CO,
Sand, etc
 Foam System for firefighting is being/will be provided to control fire from the alcohol storage
tank. The foam thus produced suppresses/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 is being/will also be cooled by the water content of the
foam.
 The foam blanket suppresses/will suppress 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).
 A team of security Guards is kept to maintain security round the clock in whole of the factory
area. The Company has fully trained operating and security staff for fire fighting and fire drill is
conducted by the fire experts on regular intervals.
 ACCIDENTAL RELEASE MEASURES: For Spill Cleanup well ventilation, shutting off or removal of all
possible sources of ignition, absorbance of small quantities with paper towels and evaporate in safe

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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 is being/will be promoted.
 Action to be taken by the First Person noticing the Fire/Leakage /Failure:
a) If it is a small fire, try to extinguish with fire extinguishers.
b) After noticing the fire, immediately call for assistance by shouting “Fire Fire” or by using
telephone facilities inform shift in-charge on intercom.
c) Inform security on intercom
Whenever disaster occurs, the incident should be communicated to the concerned authority in
minimum possible time, in case of failure of a means of communication due to electrical failure an
officer should rush to the nearest public telephone booth/ police station to transmit message through
line or police wireless.
During office hours on a working day
During office hours on working days senior most executive in the factory will take the charge of site main
controller in case of any emergency. In case of incident controller is not present in the factory production
chemist shall take over the function of incident controller as indicated in the organization chart.
1.2 Emergency Planning

1.2.1 Emergency Control Center
Emergency Control Centre (ECC) is a cell from which emergency operations are directed and coordinated.
This center activates as soon as on-site emergency is declared.
General Description of ECC
The ECC is 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 has 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.
For the purpose of handling emergency, emergency control center has been identified and shown on the site
plan. All communications to and from will originate at this control center. The emergency control center will
have the following: -
 Updated copies of the on–site Disaster Management Plan.
 Emergency telephone numbers.
 The names, phone number, and address of external agencies, response organizations and neighboring
facilities.
 The adequate number of telephone (more than two).

3.3 to 13.5 MW
 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.
EMERGENCY ORGAINZATION CHART
1.3 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:

3.3 to 13.5 MW
• 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.
1.3.1 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.
1.3.2 Alarm System

A siren has been provided under the control of Security office in the plant premises to give warning. In case
of emergencies this is used on the instructions to shift in charge that is positioned round the clock. The
warning signal for emergency is as follows:
 Emergency Siren: Waxing and waning sound for 3 minutes.
 All clear signal: Continuous siren for one minute
1.3.3 Communication
Walkies & Talkies are located at strategic locations; internal telephone system EPBX with external P&T
telephones are provided.
1.3.4 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–

3.3 to 13.5 MW
statutory and insurance requirement of Tariff Advisory Committee (TAC) of India. The complete fire
protection system comprises of the following.
(a) Fire brigade
Automatic / manual fire detection & alarm system
(b) Fire Hydrant
Fire hydrant will be provided at all around in the plant as per TAC Norms.
(c) Portable fire extinguishers
Various areas of the plant will have one or more of the above system depending upon the particular nature
of risk involved in that area.
(d) Portable chemical fire extinguishers
These are intended as a first line of defense, and hence are stationed at strategic locations in different
buildings and also for outdoor facilities. Portable fire extinguishers are of foam type; carbon dioxide type and
multipurpose dry chemical (MPDC) type.
(e) Fire detection and alarm system
Fire detection and alarm system an effective means of detection, visual indication of fire location and audible
alarm of any fire at its incipient stage. This system will comprise fire alarm panels, automatic fire detectors,
manual call points and fire siren (hooter).
The main fire alarm panel provides both visual and audible alarm of fire in any protected areas of the plant.
Manual break glass type fire alarms are provided at strategic locations where high hazards exits.
Automatic fire detectors are provided in plant areas such as control rooms, switchgear rooms, cable galleries
etc.
1.3.5 Fire -fighting groups

The Fire Fighting groups are classified into three teams, Fire-in-chief who co-ordinates all the groups shall
be safety officer:
a) Fire Fighting Team:-
I. This team will be doing the first line firefighting.
II. This team will be headed by shift in-charge/production chemist.
III. This team will be assisted by all employees in the plant and those near the place of fire.
b) Assisting Team:-
I. This team will assist the fire-fighting team.
II. This team will be headed by Maintenance Head.
III. This team shall be assisted Quality Control, production and Maintenance employees.
c) Rescue Team:-
I. This team will communicate with outside agencies and arrange first aid.
II. This team shall be headed by accounts in-charge.
III. This team shall be assisted by all employees in administrative office and medical services.
Action to be taken by different types of teams (name and action is as below):

3.3 to 13.5 MW
Action by Fire Fighting team: -

 Employees in the production department shall stop all their operations except emergency cooling.
 Fire pump operator will ensure that the hydrant and sprinkler lines have sufficient pressure.
 Employees working in production shall put off all the electrical supplies. If the accident occurs during
the night hours, the lighting switches shall be kept on.
Action by Rescue Teams
 All office staff on hearing the alarm shall remove the important documents to a safe place.
 Cashier shall lock the cash and related documents in the locker.
 The group in-charge shall depute the employees for various jobs as mentioned below.
 One employee shall take charge of telephone and contact fire brigade, police, neighboring industries
and hospitals for assistance.
 One employee shall regulate the traffic at main gate.
 One employee shall guide all outside of the plant.
 One employee shall go around the plant and ensure all plants and machineries are closed.
 Rest of the employees shall carry first aid box, various fire-fighting equipment from stores to the place
of fire.
Action plan for fire/Explosion during night:
 Persons observing the fire/leakage should raise alarm by shouting and operate the nearest available
hand siren.
 On hearing the hand siren, the watchman at the main gate shall operate electric siren intermittently to
communicate emergency.
 Efforts should be made to put off the fire using fire extinguishers, sand buckets, hydrants and
sprinklers in the area.
 All the electric supply (except lighting if it is night time) should be put off.
 Shift in-charge should contact chief technical manager, factory manager, and occupier and apprise
them of the situation. If needed police, fire control, civil hospital and neighboring industries to be
contacted for help.
First Aid
A first aid center with adequate facilities has been provided. It is being/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 are being/shall be taken care of by CSO
assisted by a Fire In charge. The team, apart from the normal security functions manages/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.

3.3 to 13.5 MW
Evacuation Procedure
If it becomes necessary to have an emergency evacuation the Emergency Controller will make the decision.
On sounding of the emergency siren the employees are expected to move to the Emergency Assembly point
(main gate). This excludes the emergency staff. Emergency Controller will give instructions for evacuation by
the emergency staff, which will then proceed to the assembly point.
If there are employees left behind in different sections, the Incident controller will organize a rescue.Decision
to allow reentry shall be taken by the Emergency Controller.
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.
Mock Drill
Mock Drill is being/should be carried out at a minimum frequency of once every six-month.
External mock drill with external authorities at an annual frequency is desirable.
Training
Adequate training is being/to be given to all JundlaTeam Members including regular Contractors and
Security. Special Training is being/to be given to the Emergency Task Force on Area Specific Emergency
Response. Specific training is being/to be given to Security for normal as well as Nightshift Emergency
Response.
Rehearsal and Updating of Plan
Emergency plans need to be tested when first devised and thereafter to be rehearsed at suitable intervals.
Individual personnel with duties under the plan should be qualified by exercise which will help to refine the
procedures by identifying deficiencies, difficulties and monitoring response time. To create awareness about
safety and emergency response procedure among the personnel, mock drill should preferably be carried out
monthly.
Rehearsals or exercise are important for all personnel likely to be involved in an accident on or off the site
because:
I. They familiarize on-site personnel with their roles, their equipment and the details of the plans.
II. They allow the professional emergency services to test their parts at the plan and the co-ordination
of all the different organizations.
III. They provide the current accuracy of the details of the plan (telephone numbers etc.) and the
availability of special equipment (fire and rescue breathing sets etc.)
IV. They give experience and build confidence in the team members. In the initial shock and confusion
of real incident, the ability to fall back on established initial actions are invaluable.

3.3 to 13.5 MW
The on-site emergency procedures for each process plant, storage facility etc. should be tested regularly and
that all employees receive initial and refresher training, exercise should be arranged to test each part of the
emergency plan on each plant, stage by stage. Emergency isolation and shut down should be rehearsed.
After each rehearsal or practice, the plan should be reviewed to take account of any shortcomings
highlighted by the exercise.
1.4 Emergency Response & Responsibilities

1.4.1 Person Discovering Fire / Possible Emergency Situation
• In case of fire shout “FIRE" and inform concern authority & security for blowing the emergency siren.
• In case of Spillage / Other Emergencies try to control locally. If it cannot be controlled locally
informsecurity for blowing the emergency siren.
• Inform Plant Manager / Shift In charge about the incident when he reaches the incident site with
details of place, magnitude of mishap and follow instructions.
1.4.2 Security Services

GENERAL SHIFT HOURS
• Blow the emergency sire.
• Ensure Emergency Vehicle is ready for Action.
• Ensure both gates are clear.
• Arrange to relocate tankers to safe location
• Be available at the Main gate to assist the Emergency Admin Controller.
OUTSIDE GENERAL SHIFT HOURS
• Blow the emergency sire.
• Ensure Emergency Vehicle is ready for Action.
• Ensure both gates are clear.
• Arrange to relocate tankers to safe location.
• Inform people as per emergency roll call chart displayed.
• Be available at the Main gate to assist the Emergency Admin Controller.
• Do not talk to external world till emergency controller arrives.
1.4.3 ROLE OF EMERGENCY TASK FORCE

• Emergency task force becomes aware of the Site of Emergency either through direct sight as in their
work area or through the phone.
• ETF Members should proceed straight to the Incident Site and follow the instructions of the Works
Incident Controller.
• Emergency Task force should control the event without endangering themselves.
• Fire Fighting & Manhunt should be done with due precaution
Person Raw water system
• Ensure water supply in the fire hydrant points.

3.3 to 13.5 MW
• Ensure all Borewell are running

Person in Electrical PCC Room
• Ensure electrical supply to raw water system
• Maintain vigil on Power availability
• Start DG Set and keep it on Standby.
Person for First Aid
Provide First aid and required help
1.4.4 Asst. Vice President (Works) as Emergency Controller

Immediately he is aware of the emergency, The Emergency controller will proceed to the Emergency Control
Centre (AVP Office) through the Site of Emergency. He will remain at the Emergency Control center till
cessation of Emergency. In absence of AVP (works), Asst Manager (CPU) & General Manager Bottling shall
jointly become emergency controller.
• Assess and evaluate the scale of emergency and activate the emergency plan accordingly.
• Ensure that the emergency services have been called in and where required that nearby firms have
been informed. Relevant authorities for public facilities must also be contacted as appropriate.
• Ensure that all key personnel have been called in.
• Inform the necessary External agencies including HLPL Senior Management of the emergency.
• Exercise direct operational control of those parts of site outside the affected area.
• Maintain continuous review of possible developments and direct shutting down and evacuation of
plant in consultation with the Works Incident Controller.
• Ensure that casualties are receiving adequate attention. Arrange for additional help if required. Ensure
that relatives are advised. Communications are passed on to OHC through security.
• Liaise with chief officers of Emergency and Police services, Health and Safety authorities.
• Provide advice of possible effects on areas outside the works.
• Ensure that all Personnel are accounted for.
• Arrange traffic control at site.
• Liaise with media spokesperson.
• Arrange for chronological record of the emergency to be maintained and ensure that evidence is
preserved for enquiries conducted by statutory authorities.
• Where the emergency is prolonged, arrange for relief of personnel and the provision of catering
facility.
• Control rehabilitation of affected area on cessation of emergency.
• Revoke emergency after the situation has become normal.
1.4.5 Role of Incident Controller

It is the duty of the Works Incident Controller to reach the scene of the incident as quickly as possible and
assess the situation. He will remain at the incident site till cessation of emergency. On arrival at incident
site he will:

3.3 to 13.5 MW
1. He will assess the scale of emergency and send information to the Emergency Controller through
phone or through any of the emergency task force member
2. Direct the safe shutting down of operations and try to minimize the damage to plant property and
environment.
3. Ensure that all key personnel and help from fire brigade/first aiders/hospitals are called for through
Emergency Controller
4. Co-ordinate operations on Incident Site.
5. Assume duties of Emergency Controller until he is in position. In particular ensuring that emergency
services and key personnel on site are informed of the situation.
6. Communicate continually with Emergency Controller and inform all developments as appropriate.
7. Conduct search for casualties.
8. Liaise with Emergency Task Force during the incident.
9. Ensure that any evidence which may be required for further investigation is Preserved.
11. Ensure that after cessation of emergency, emergency task force members are safe
1.4.6 Role of Communication Controller

It is the duty of the Communication Controller to reach the control room of the incident as quickly as
possible and assist the emergency controller. He will remain at the control room till cessation of
emergency. On arrival he will:
1. He will advise the Site Emergency Controller of the situation, recommending (if necessary) evacuation
of the staff from assembly points.
2. Assist Emergency Controller in communicating nature of assistance required from Civic
Authorities (District Magistrate's Office, Police etc.)
3. Assist Emergency Controller in declaring Major Emergency to the Civic Authorities like District
Emergency Authority
4. Keep necessary transport at the Gate Office.
5. Co-ordinate Traffic at Site under advice from Emergency Controller.
6. Receive instruction from the Emergency Controller for any assistance from thefollowing authorities
and manage relationship / communication with them:
 Hospitals
 Fire Brigade
 Police
 Ambulance
7. Communicate Termination of Emergency under advice of the Emergency Controller.
1.4.7 Role of Engineering Co-Ordinators
It is the duty of the Engineering coordinators to reach the incident site and coordinate with the incident
controller.
1. Co-ordinate closes down of services.
2. Ensure Electrical Team has assumed position at the Substation with his emergency team.
3. Ensure for the water supply and safety equipment.

3.3 to 13.5 MW
1.4.8 Emergency Administration Co-coordinator: Asst. Manger HR

On becoming aware of the Emergency, The Asst Manager HR, shall proceed to the Main gate Security Office.
He will remain there till cessation of Emergency. On reaching there he will:
1. Obtain the number of people at site from Security.
2. Keep necessary transport at the Gate Office
3. All incoming people should be retained at the Gate Office
4. Assist Emergency Controller in declaring Major Emergency to the Civic Authorities like District
Emergency Authority.
5. Keep necessary transport at the Gate Office
6. Direct relief team (selected by him at spot ) to proceed to the Emergency site along with First Aid Kits
under advise of the Emergency Controller.
7. Co-ordinate Traffic at Site under advice from Emergency Controller
1.4.9 Asst Works Incident Controller: Shift In charge

On becoming aware of the emergency, the Shift Officer, shall proceed to the place of Incident. He shall assist
the Works Incident Controller in execution of his responsibilities. After Office hours he shall assume the role
of full Works Incident Controller
1.4.10 Off-site emergency control plan:

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.
Action Plan:-
The site Main Controller will assess the situation and if the emergency is likely to spread outside the
installation or affect the neighbor industry and people outside the factory premises, will declare off-site
emergency. He will coordinate with the incident controller and get intouch with all essential local authorities
and mutual aid members for controlling the disaster. The local authorities will work under the direct
supervision of the site Main Controller.
The help of the following agencies is summoned: -
 Local police
 Fire Brigade
 Hospitals
 Ambulance
 Blood Banks

3.3 to 13.5 MW
 Home guards
 Voluntary Agencies.
Table: 4
Emergency contact no. of various organizations involved during emergency
S.No. Name Telephone No.

1. Fire Brigade 0184-2253799, 0184-2270799
2. Police Station 01745274159
3. Hospital 0174-5274284, 0184-2266252
4. Ambulance 9468090885
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 7.1: 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.

3.3 to 13.5 MW
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 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 BrigadeThe fire brigade is to be organized to put out fires and provide assistance as required
during emergency.
Media
• The media needs 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

3.3 to 13.5 MW
• 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 Centres 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.
1.5 OCCUPATIONAL HEALTH AND SAFETY MEASURES

To control and minimize the risks at workplace, Haryana Liquors Pvt. Ltd. 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.
1.5.1 Occupational Health and Safety Hazards

(1) Dust
A) Risks involved
Following risks are involved:
• Presence of dust may cause respiratory disorders
• Systemic intoxications
B) Management Measures
• Implementation of adequate dust control systems and good housekeeping.
• Water sprinkling in the places where dust dispersion can occur.
• Regular sweeping of roads within plant premises
• Providing dust masks to employees working in handling and storage yards.
(2) Noise
A) Risks involved
Following risks are involved:
• Hearing Impairment, Hypertension, Increase Pulse rate
• Annoyance, Tinnitus, Sleep Disturbances
• 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

3.3 to 13.5 MW
• Periodic health checkup will be kept as audiometric records for the persons working in high noise
area.
(3) Heat stress
A) Risks involved
• Increase in core body temperature which leads to dehydration
• Increase in heart rate and muscle cramps
• Heat exhaustion
B) Management measures
• 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
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 is being/will be done as per IS 3043
• Low Voltage Supply is being/will be ensured
• Isolating Transformers
• Double Insulated Tools
• Over Load Protection
• Protection Against Leakages (G.F.C.I.)
• Flame- Proof Equipment
• Lightning Protection
(5) Fire and Explosion
A) Risks involved
• Fire catching in store, bag godown, conveyors, oil storage area, fuel storage yard, transformers
etc.
• Suitable fire extinguisher, fire hydrant system and fire buckets. Dry power type in oil and fire
buckets are kept near transformer, cable, general store and office area. Fire tender is kept ready at
plant main gate.
• Oil and Flammable Gases storage area fenced and declared as Fire Hazardous Area-“No Smoking
Area”

3.3 to 13.5 MW
• Permit and safety instruction to use welding / gas cutting in the area of oil storage, coal storage
and godown.
• 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 Buildings 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
• Installation of light arrestors at all tall 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 is maintained in air receiver.
• Safe working load for cranes and ropes etc.
• Good housekeeping & Speed limit of 20 km/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 are kept at the sites and training provided.
• Use of mobile while driving, alcohol, smoking etc are ban in plant area.
• Proper illumination in office
1.5.2 Occupational Health Surveillance

In the plant, the occupational health surveillance of the employee is being/will be done on a regular basis
and records of the same are being/will be maintained as per the Factories Act. The occupational health
surveillance program will include/includes 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 programs are being/will also be conducted. Under vocational training the workers are
being/will be given training related to all safety and health aspects pertaining to their vocation and thereafter
every quarter special training courses/ Awareness program for Malaria eradication, HIV and health effects on
exposure to dust, heat, noise, chemicals are being/will be organized for employed person.
Periodical medical camps with specialized doctors of various disciplines will also provide/provides the
specialized medical assistance to employees as well as neighboring communities.

3.3 to 13.5 MW
A. Pre placement and periodical health status

Pre / Post-employment checkup will be carried out and following tests are being/will be conducted:
 Chest X- rays
 Audiometry
 Spirometry
 Vision testing (Far & near vision, color vision & other ocular effect)
 ECG
 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 are being/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 are being/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
D. Details of Test conducted
Details of various test conducted of the working employees is done.
F. Anticipated occupational & safety hazards
 Heat Stress and Stroke
 Physical activity
 Dehydration
 Cardiovascular disease

3.3 to 13.5 MW
 Skin disorders
 Dust Exposure
 Metallic dust exposure
 Noise
 Burns and shocks due to electricity
1.5.3 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 have been 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
 Implementation of OHSAS 18001 for Occupational Health and Safety Management System
 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 and near miss accident
 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 campaigns, competitions, contests etc. to promote safety
 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 manures
 Display Material Safety Data Sheets (MSDS) for use of every hazardous substance

3.3 to 13.5 MW
 Implement the recommendations of HAZOP (A 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
1.5.4 Safety Committee

A safety committee is 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.
1.5.5 Medical Facilities

The company has/will be provided with occupational health centre functioning round the clock along with
the trained staff. The company has facility for ambulance for the workers. Tie up arrangements are/will be
there with nearest hospital and nursing home for the plant. First aid boxes are/will be kept in all identified
locations for emergency.
Apart from these, specialists will visit/visits the Plant to render consultation. Camps for immunization, family
planning, blood donation and free medical checkup programs are being/will be organized on regular basis
for employees as well as neighboring communities.
First Aid Boxes
First aid boxes have been/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 (2cm x 1 m).
 Sterilized eye pads in separate sealed packets.
 Aspirin tablets.
 Potassium Permanganate crystals.
First aid boxes are being/will be kept in every department for emergency. First aid training will be organized
for the employees.

3.3 to 13.5 MW
1.6 PLAN & FUND ALLOCATION FOR OCCUPATIONAL HEALTH & SAFETY
Proposed budget details for expenditure on Occupational Health & Safety will be Rs 20 lakhs/annum.
Table: 5
Fund allocation for Occupational Health & Safety
Particular Amount (Lakhs)

Estimated Expenses on worker health checkup 6
Doctor fees & other facilities 14
Total Budget 20
1.7 CONCLUSION
It is concluded that there will be no major risk involved due to installation project. Proper precautionary
measures are being/ will be taken to minimize risks. Personal Protective Equipment (PPEs) will help to
minimize the health hazards and accidental casualties. So, it is safe to say that there will be no major risk
involved due to the installation project.

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Expansion of Grain based Distillery from 165 KLPD to 465 KLPD by installation of new 300 KLPD Ethanol Plant

& Co-Generation Power Plant from

RISK ASSESSMENT REPORT

1.0 RISK ASSESSMENT

1.1 Hazard Identification & Risk Assessment (HIRA)

Haryana Liquors Pvt. Ltd.

S. No. Name Description Severity Hazard

1.1.2 Types of Accidents Possible

Causes of Incident Relevance for Jundla Works

Causes of Incident Relevance for Jundla Works

1.1.3 Assessment of Risk along with mitigation measures

Haryana Liquors Pvt. Ltd.

S. Associated Associated risk/ Risk

1. Storage & Bursting of Exposure, physical H • Use of PPEs.

2. Working near Heat & Fire Physical injuries H • Firefighting facility

6. Storage of Exposure, Exposure to over H • Well ventilation

8. Release of high Explosion Risk of severe H • Regular maintenance & inspection of

Haryana Liquors Pvt. Ltd.

S. Associated Associated risk/ Risk

9. Electrical Electric shock, Electrical shocks, H • Regular checking and maintenance of

Haryana Liquors Pvt. Ltd.

Haryana Liquors Pvt. Ltd.

1.1.4 Safety Measures for Storage & Handling of Alcohol

Haryana Liquors Pvt. Ltd.

1.2 Emergency Planning

Haryana Liquors Pvt. Ltd.

 Emergency lights, Clocks, Personal protective equipment.

1.3 DISASTER MANAGEMENT PLAN

Haryana Liquors Pvt. Ltd.

• To localize the emergency and, eliminate it; and

1.3.2 Alarm System

1.3.4 Fire Fighting System

Haryana Liquors Pvt. Ltd.

1.3.5 Fire -fighting groups

Haryana Liquors Pvt. Ltd.

Action by Fire Fighting team: -

Haryana Liquors Pvt. Ltd.

Haryana Liquors Pvt. Ltd.

1.4 Emergency Response & Responsibilities

1.4.2 Security Services

1.4.3 ROLE OF EMERGENCY TASK FORCE

Haryana Liquors Pvt. Ltd.

• Ensure all Borewell are running

1.4.4 Asst. Vice President (Works) as Emergency Controller

1.4.5 Role of Incident Controller

Haryana Liquors Pvt. Ltd.

1.4.6 Role of Communication Controller

Haryana Liquors Pvt. Ltd.

1.4.8 Emergency Administration Co-coordinator: Asst. Manger HR

1.4.9 Asst Works Incident Controller: Shift In charge

1.4.10 Off-site emergency control plan:

Haryana Liquors Pvt. Ltd.

S.No. Name Telephone No.

Figure 7.1: Various organizations involved during emergency

Haryana Liquors Pvt. Ltd.

Haryana Liquors Pvt. Ltd.

1.5 OCCUPATIONAL HEALTH AND SAFETY MEASURES

1.5.1 Occupational Health and Safety Hazards

Haryana Liquors Pvt. Ltd.

Haryana Liquors Pvt. Ltd.