Rama Pulp & Paper Ltd

Risk Assessment

7.1 Risk Assessment

Industrial accidents result in great personal and financial loss. Managing these accidental
risks in today’s environment is the concern of every industry including chemical fertilizers,
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, environment, or public.
Risk analysis involves the identification and assessment of risks; the neighboring populations
are exposed to as a result of hazards present in the plant operation. This requires a thorough
knowledge of failure probability, credible accident scenario, vulnerability of populations etc.
The risk analysis is often confined to maximum credible accident studies. In this chapter, the
identification of various hazards, probable risks in the proposed SSP/LABSA (Powder and
granular) manufacturing plant, maximum credible accident analysis, consequence analysis
are addressed, which gives a broad identification of risks involved. Based on the risk
assessment, disaster management plan has been presented.
The main objective of risk assessment study is to propose a comprehensive but simple
approach to carry out risk analysis and conducting feasibility studies for industries, planning
and management of industrial prototype hazard analysis study in Indian context.
Quantitative Risk Assessment (QRA) may be carried out to serve the following objectives:
 Identification of safety areas
 Identification of hazard sources
 Generation of accidental release scenarios for escape of hazardous materials from the
facility
 Identification of vulnerable units with recourse to hazard indices
 Estimation of damage distances for the accidental release scenarios with recourse to
maximum credible accident (MCA) analysis
 Estimation of probability of occurrences of hazardous event through fault tree analysis
and computation of reliability of various control paths
 Assessment of risk on basis of above evaluation against the risk acceptability criteria
relevant to the situation
 Suggest risk mitigation measures based on engineering judgment, reliability and risk
analysis approaches
 Delineation /update DMP
 Safety Reports: with external safety report/ occupational safety report,
 The risk assessment report may cover the following in terms of the extent of damage with
resource to MCA analysis and delineation of risk mitigations measures with an approach
to DMP.
 Hazard identification – identification of hazardous activities, hazardous materials, past
accident records, etc.
 Hazard quantification – consequence analysis to assess the impacts
 Risk mitigation measures
 Disaster Management Plans

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7.1.1 Hazard Identification

Identification of hazards in the proposed plant is of primary significance in the analysis,

Quantification and cost effective control of accidents involving chemicals and process. A
classical definition of hazard states that hazard is in fact the characteristic of
system/plant/process that presents potential for an accident. Hence, all the components of a
system/plant/process need to be thoroughly examined to assess their potential for initiating or
propagating an unplanned event/sequence of events which can be termed as an accident.

7.1.2 Hazard Assessment and Evaluation

A preliminary hazard analysis is carried out to identify the major hazards associated with
storage and the process of the plant. This is followed by consequence analysis to quantify
these hazards. Finally the vulnerable zones are plotted for which risk reducing measures are
deduced and implemented.
Physical and Health Occupational Hazards in any large scale Chemical /Hydrocarbon
Processing
Industry (CPI/HPI) can be broadly classified into the following categories:
 Mechanical Risks
 Electrical Risks
 Fire/Explosion Risks
 High /low Temperature Exposure Risks
 Toxic/Carcinogenic Chemicals Exposure Risks
 Corrosive/Reactive/Radioactive Chemicals Exposure Risks
The first two types of risks are of universal nature associated with any industrial activity and
not specific to a particular plant or process.

Mechanical Risks
Mechanical risks which are generally encountered are injuries to the head, Limbs, eyes, etc
usually as a result of negligence on the part of operating/maintenance personnel in the use of
improper tools, bypassing prescribed safety procedures neglect of personal protective wear
and risks associated with rotating machinery as well as risks associated with high-energy
release from compressed gases. Electrical risks which result in shock and/or burns are most
often a consequence of poor maintenance, ingress of dust or moisture, handling by
unauthorized personnel and use of improper/substandard hardware.
Electrical Hazards
Electrical hazards leading to fire and explosion in switchgear and other equipment mainly
due to failure of circuit breakers, insulators, fuses, bus bars, and poor maintenance. Accidents
may also occur in transformer due to open arcing, flashover above oil level, insulator failure,
overloading, failure of air cooling system, lighting etc. Nevertheless, all these hazards lead to
localized accidents only.
Fire Hazards
There could be other areas in the plant that have a potential for fire hazard and require
adequate firefighting equipment for example, the fuel storage. These are considered here
since uncontrolled fire may trigger the above emergencies due to domino effect. However for
the proposed plant, safety guidelines will be as per Tariff Advisory Committee.

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Toxic release
The proposed plant will use Sulphuric acid which is corrosive and toxic. If sulphuric acid
will not handled properly it will lead to toxicity and burns. Self contained breathing
apparatus will be available in the premises in the event of leakage in case of emergency.
Employees will be trained in handling these self contained breathing apparatus. Since the
quantity of toxic release will be on lower side, offsite implications of release are not
envisaged.

Hazardous Chemicals Release

There are various hazardous chemicals (toxic and flammable), which will be used as raw
material for manufacturing of SSP in the plant. Separate storage area will be provided for
these chemicals and will be handled with at most care following the safety norms for
handling of hazardous chemicals. Bulk storages are provided for those chemicals, which will
be required in the large quantity and are flammable/toxic in nature. The storage tanks will be
in the isolated zone and will have fire water hydrant system. The details of bulk chemical
storage are given in Table 7-1.

Table 7-1: Chemical Storage details

Sr. Particulars Number of tanks Capacity of Storage Category
No.
1 Sulphuric Acid Three 1500 MT Corrosive

Properties of the chemicals are mentioned in below.

1. Sulphuric Acid:
a. It is highly corrosive in nature.
b. Specific gravity is 1.84 (water = 1).
c. Vapor Density is 3.4 (air = 1).

Preliminary Hazard Analysis for Process and storage areas is mentioned in Table 7-2

Table 7-2: Preliminary Hazard Analysis for Process and storage areas
Sr. Blocks/ Area Capacity / Hazard Identification
No. Quantity
1 Flammable Chemical 200 Ltr Fire, Spontaneous Combustion
Storage (HSD)
2 Power Transformers - Explosion and Fire
3 Switch – yard Control - Fire in cable galleries and Switchgear /
Room Control Room.
4 Process reaction vessels - Fire due to accidental spill, leakages of
flammable raw material from the
equipment.
Preliminary Hazard analysis for whole plant in general is mentioned in Table 7-3.

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Table 7-3: Preliminary Hazard analysis for whole plant in general

Sr. PHA Description of Plausible Provision
No. Category Hazard
1 Environmental If there is any leakage All electrical fittings and cables are
Factors and eventuality of source provided as per the specified standards.
of ignition
Highly inflammable A well designed fire protection
nature of the chemicals including dry powder, CO2 and foam
may cause fire hazard in extinguisher should be provided. Fire
the plant. extinguisher of small size and big size
are provided at all potential fire hazard
places. In addition to the above, fire
hydrant network is also provided to
required locations in plant.

7.1.3 Safety Measures

Following safety measures will be provided to ensure safe operations:
 Applicable standards will be followed in the design of equipment.
 Piping for flammable liquid will be provided with continuity jumpers and earthing.
 Safety valve will be provided as per requirement
 Fire protection system will be provided to locations handling flammable liquids and
appropriate type of fire extinguishers will be provided.
 Fire alarm system will be provided in plant identified risk areas
 Adequate Process safety interlocks shall be included in the design
 Standard operating procedures (SOP) will be provided for each unit operation
 On site emergency plan have been prepared for the onsite emergencies
 Adequate Personal Protective Equipment (PPE) such as hand gloves, safety goggles,
helmets, safety shoes, protective clothing, apron, respirators will be provided
 First aid and fire fighting training will be provided to all the employees
 Work permit system will be applied to the major installations
 Pre employment and periodic medical checkup will be carried out.

Specific Safety Measures Related to Sulphuric Acid Storage & Handling

Sulfuric acid is a corrosive, oily, colorless liquid when pure. Sulfuric acid is most often used
as a chemical intermediate to manufacture other chemicals.
Common Routes of Sulfuric Acid Exposure:
 Inhalation - The most common way for sulfuric acid to enter the body is through the
respiratory system. Serious lung damage may result from inhalation exposure to sulfuric
acid.
 Contact with the Skin - Sulfuric acid can irritate the skin and cause chemical burns
ranging from mild to severe, depending on the concentration of the sulfuric acid solution.
Concentrated vapor or solution that contacts the skin may cause the victim to experience
severe pain, redness of the skin, blisters and necrosis.

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 Contact with the Eyes - Sulfuric acid or sulfuric acid vapor, even with short term
exposure, can irritate the eyes and cause burning, swelling, tearing of the eyes and/or
blurred vision, and may cause blindness.
 Ingestion - Immediate burning in the mouth and throat occur when sulfuric acid is
swallowed. Ingestion of concentrated solution can cause severe pain in the mouth, chest
and abdomen, nausea and vomiting, or perforations in the esophagus.

Acute Health Effects of Sulfuric Acid Exposures:

As the concentration of sulfuric acid increases, the symptoms become more severe. Acute
exposures to sulfuric acid can cause immediate burning of the eyes. Itchy, burning eyes can
help to warn people of potentially hazardous exposure levels. The very young, the very old,
and people with health problems are at an increased risk from the health effects of sulfuric
acid exposure.

Chronic Health Effects of Repeated Exposure to Sulfuric Acid:

Erosion of the teeth, gastric strictures, chronic bronchial irritation with cough, and/or chronic
shortness of breath may occur with repeated or long-term exposure to sulfuric acid. Skin
rashes may also occur with repeated exposures of dilute concentrations of sulfuric acid.

Proper Handling and Storage Procedures:

Before working with sulfuric acid, individuals will be trained in its proper handling and
storage and know how to use proper personal protective equipment. Sulfuric acid will be
stored in a cool, dry, well ventilated area in tightly sealed containers protected from exposure
to weather, extreme temperature changes, and physical damage. Sulfuric acid is incompatible
with organic materials and metals.
Contact with either of these materials can cause fire and explosions, or generation of toxic
sulfur dioxide fumes and flammable hydrogen gas.
If a fire occurs in the immediate vicinity of sulfuric acid containers, will be removed
promptly if it can be done safely. If removal will not be possible, use of dry chemical or
carbon dioxide to extinguish the fire for small fires. For large fires, flood the fire area with
water from a safe distance. When water is applied directly to sulfuric acid, heat evolves and
spattering may occur. When heated, sulfuric acid emits highly toxic fumes, so firefighters
would use positive-pressure breathing apparatus.

Personnel Protective Equipment:

Clothing
Skin contact with sulfuric acid will be avoided. Chemical-resistant clothing and protective
gloves (Nitrile and natural rubber gloves are best suited for prolonged contact with sulfuric
acid, but vinyl gloves are also acceptable) will be provided to the workers.

Eye Protection
Employees will use splash-proof goggles when there will be any possibility of sulfuric acid
exposure.
An eye-wash fountain or an eye wash kit for emergency responders will be available if there
will be any possibility of the eyes coming in contact with a solution or liquid sulfuric acid
with more than 1 %sulfuric acid by weight.

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First Aid Management:

Prompt action will be taken if there is a sulfuric acid spill or leak. If a sulfuric acid spill or
leak occurs, following actions will be taken:
 Breathing
If sulfuric acid is inhaled, person will be moved to the fresh air at once. If breathing
stops, artificial respiration will be performed. Affected person will be kept warm and
resting and medical attention will be provided immediately.
 Eye Exposure
Eyes will be washed immediately with large amounts of water for at least 15 minutes,
lifting the upper and lower lids. Medical attention will be provided immediately. Contact
lenses will not be worn when working with sulfuric acid.
 Skin Exposure
Skin contaminated with sulfuric acid will be flushed with soap and water for at least
15minutes. If strong concentrations of gas or solution penetrate clothing, then cloths will
be removed and skin will be flushed with water. Medical attention will be provided
immediately.
 Swallowing
If sulfuric acid solution is swallowed, and the person is conscious, large amounts of water
or milk will be given to dilute the sulfuric acid solution. Attempt to vomit by exposed
person will be allowed. Medical attention will be provided immediately. Material safety
data sheet (NISDS) will be referred or a physician will be called.

Spill Management:
If a sulfuric acid spill or leak occurs, following actions will be taken:
 Trained personnel will be called immediately, such as the company fire officer or the
local fire department. Untrained persons or those without proper personal protective
equipment will not allowed enter in areas with high concentrations of sulfuric acid.
 Evacuation and restriction of people from the hazardous area of a sulfuric acid release.
 Stop or control the source of exposure.
 Ventilation of contaminated atmospheres by opening windows to disperse the fumes.
 If the exposure is from the spill of a solution, collection of the spilled material. Dilution
and neutralize of the spill and dispose in a secured landfill.

7.2 Disaster Management Plan

The DMP is supposed to a dynamic, changing, document focusing on continual improvement
of emergency response planning and arrangement. A structure working on a Plan, Do, Check
and Review (PDCR) cycle has been therefore suggested. A person, head of operations, will
be deployed who will be in-charge of overall disaster management system.
7.3 Policy
The Environment, Health and Safety (EHS) policies are to be made accessible to all at site
and to other stakeholders. The policies must be framed considering legislative compliance,
stakeholder involvement, continual improvement, and management by objectives.

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7.4 Planning

7.4.1 Identification and Prevention of Possible Emergency Situations Identification of

Emergencies
Possible emergency situation can broadly be classified into toxic release, fire or explosion,
while doing so, it is stressed that these results are only for the modeled scenarios and, that the
distances as well as damages can change depending upon the actual development of a
scenario. Additional emergency situations can be developed on the basis of audit / HAZOP
or other procedures prior to commencement of operations.

Emergency Prevention
Some of the ways of preventing emergencies are as follows:
 Preparation of a Preventive Maintenance Category Programme covering maintenance
Category for all critical equipments and instruments as per recommendations of the
manufacturer’s user manuals.
 Establishment of a computerized Failure Modes Effects and Criticality Analysis
(FMECA) or similar procedure to generate data on failures of critical equipments and
instruments based on mode wise failures and their criticality. This requires codification of
equipments, instruments and their modes of failure and their criticality. Consideration
may be given to the use of appropriate software for processing FMECA data for review
of the Preventive Maintenance Category and for improvement of the same to ensure
critical failures,
 Establishment of a Non Destructive Testing (NDT) system as necessary. This may not be
feasible in-house but there are specialized organizations who undertake the work, and the
same may be used.
 Importantly, it is of great importance to collect and analyze information pertaining to
minor incidents and accidents at the site, as well as for recording near-misses or
emergencies that were averted. This information gives an indication of how likely or
unlikely it is for the site to face actual emergencies and what should be further done to
prevent them from occurring. Establishment of an ongoing training and evaluation
programme, incorporating the development of capabilities amongst employees about
potential emergencies and ways and means of identifying and averting the same. Most
emergencies do not occur without some incident or an abnormal situation. So there is
always sometime of few seconds to few minutes to arrest an incident of abnormal
situation from turning in to an emergency. This is the role of the shift in-charge who is
the incident controller(IC) along with his shift team.

7.4.2 Formation of Emergency Plan Objectives

Specific objectives of the Emergency Response Plan are to be clearly listed with regards to
the responses desired for successful management of the possible emergency situations.
Suggested
Objectives could, initially include:
 Formulation of suitable onsite / offsite fire release response

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 Improved awareness of safety issues amongst site personnel

 Training of key persons in cardio-pulmonary resuscitation and other first aid

The objectives suggested currently are generic in nature. However, they will evolve and
become more specific as the project develops further. Responsibilities, resources and
timeframes require to be allocated for implementing the objectives.

7.4.3 Formation of Emergency Plan Objectives

Specific objectives of the Emergency Response Plan are to be clearly listed with regards to
the responses desired for successful management of the possible emergency situations.
Suggested
Objectives could, initially include:
 Formulation of suitable onsite / offsite fire release response
 Improved awareness of safety issues amongst site personnel
 Training of key persons in cardio-pulmonary resuscitation and other first aid
The objectives suggested currently are generic in nature. However, they will evolve and
become more specific as the project develops further. Responsibilities, resources and
timeframes require to be allocated for implementing the objectives.

7.5 Onsite Emergency Plans

7.5.1 Types of Emergencies

In an industry where various types of hazardous chemicals are handled, various processes are
carried out the following types of emergencies can occur:
 Fire, explosion or release of toxic gases
 Spillages of chemicals in large quantities resulting into pollution of land
 Collapse of building or structure due to explosion
 Release of hot material due to run away reaction resulting into person injuries to people
 Toppling of road tanker containing flammable or corrosive chemicals resulting in to
contamination of land

7.5.2 Statutory Requirement of Onsite Emergency Plan

Section 41B of Factory Act 1948 defines to draw up an Onsite Emergency Plan with
mentioned of all control measures for the industry and educate employees accordingly about
the plan. Rule 13 of Manufacture, Storage and Import of Hazardous Chemical Rules, 1989
says to prepare an Onsite Emergency Plan.

7.5.3 Hazard at Out Unit

Following hazards have been identified as emergency situation at out unit:
 Fire
 Explosion
 Release of Toxic Gases
Fire as we all know, sets up with the combination of Air, Fuel and heat sources. In an
industry it becomes utmost necessary to eliminate all sources of heat generation. Some of the
following aspect scan be ensured to remove any chances of heat / spark generation:
 Provision of Spark arrestor on all incoming vehicles

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 Installation of flame proof electric fittings in the areas where flammable chemicals are
stored or handled
 Carrying out of hot work activities with an adequate work permit
 Ensure earthing connections to equipment / vehicle wherever is required
 Prohibition of items that has a potential to create a direct spark such as matchboxes,
camera, mobile phones etc. beyond specified limit
 Usage of non-sparking tools in flameproof areas Explosion is generally occurring inside a
vessel or outside the vessel, which resulted into loss of flammable or toxic chemicals.
Release of flammable vapor during an explosion can lead to BLEVE
(Boiling Liquid Expanding Vapor Explosion), which can create havoc inside the factory as
well to the neighboring population. Release of toxic gases can occur due to failure of safety
system of the equipment or excess pressurization of reactive mass inside a vessel.
There are some other incidents that have potential to convert into a disastrous situation; those
incidents are categorized as below:
 Earthquake
 Cyclone
 Manmade War
 Sabotage

7.5.4 General Guidelines

 Site Main Controller or Incident Controller can change the guideline based on prevailing
situation.
 Fire Operator / Fireman should be available at fire station till maintenance engineer take
charge from him. After that he will follow the instructions of incident controller.
 Follow the instructions of Incident & site main controller.
 Plants and unit may be stopped as per the instructions of site main controller and incident
controller.
 Those who are not required for handling emergency or running plants should move to
assembly point.
 All employees should guide visitors or contractors to approach assembly point.
 One trained first aider must be available at the occupational health centre and assist /
coordinate factory medical officer / male nurse during emergency.
 Emergency vehicle should be available near security main gate with spark arrestor, and
rush to the emergency control centre at the blowing of emergency siren. The driver of
emergency vehicle will follow the instructions of Incident Controller / Site Main
Controller.
 The shift engineer / Electrician to get ready to manage MCC as per the instructions
Incident Controller / Site Main Controller.
The Disaster Management Plan (DMP) is a guide, giving general considerations, directions
and procedures for handling emergencies likely to arise from planned operations. Site
specific documentation contingent to – and demonstrating suitable implementation of the
DMP is described in the annexure to the DMP. The Annexure, being site specific, will
require to be updated once the actual site operations are underway.
The DMP must also be revaluated prior to start of operations and it is the responsibility of the
Plant Manager to do this. The DMP has been prepared for Narmada Bio fuel Pvt. Limited on

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the basis of the Risk Assessment and related findings covered in the earlier chapters of this
report. The results of consequence assessment for the credible scenarios indicate that the risk
contours are confined within the site boundary only.

7.6 Emergency Control

In case of emergencies, actions can broadly be categorized into the following activities:
 Saving of human lives
 Controlling the spread of the emergency and ultimately stopping it from further
developing On the basis of the issues covered in this chapter, the following are required
to be incorporated in to the CP for implementing this EP’s requirements:
 Onsite Emergency Control
 Shut down and Isolation: Raising the alarm, followed by immediate safe shut down of the
power supply, and isolation of affected areas.
 Escape, Evacuation and Rescue: Safeguarding human lives at site by commencement of
the Emergency Evacuation and Rescue Plan. Ensuring that all personnel are accounted
for and carrying out a head count of persons evacuated. Notification and commencement
of offsite emergency plan in case offsite impacts are possible.
 Stopping the development of the emergency: Control or response to the emergency
depending upon its nature (fire or explosion).
 Treatment of injured: First aid and hospitalization of injured persons.
 Protection of environment and property: During mitigation, efforts should be made to
prevent impacts on environment and property to the extent possible.
 Welfare of the personnel managing the emergency: Changeover, first aid and
refreshments for the persons managing the emergency.
 Informing and collaborating with statutory, mutual aid and other authorities including
those covered in the Local Crisis Group.
 Informing and assisting relatives of the victims.
 Informing the news and electronic media.
 Preserving all evidences and records: This should be done to enable a through
investigation of the true causes of the emergency.
 Investigation and follow up: This requires to be carried out to establish preventive
measures for the future and a review of the EP and CP to fill up the deficiencies in the
emergency planning procedures.
 Ensuring safety of personnel prior to restarting of operations: Efforts require to be made
to ensure that work environment is safe prior to restarting the work.

7.7 Off-site Emergency Response Plan

The following are the Expanded Incorporation’s responsibilities towards generation of the
Offsite Emergency Plan:
 To provide basic information on Risk and Environmental Impact Assessment to the
Local/District Authority, Police, Fire Brigade, Doctors, surrounding industries and the
public and to appraise them on the consequences and the protection/prevention measures
and control plans and seek their help to manage the emergency.
 To assist the District Authorities in preparing the Off-site Emergency Plan.
 An off-site emergency plan organization has essentially two parts:

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 Formation of the Local Crisis Group: This Group is headed by the Deputy Collector or
the Magistrate of the Industrial area and is responsible for the management of any
industrial emergency confined to the local area.
 Formation of the District Crisis Group: This Group is headed by the District Collector of
the District and is responsible for any major Industrial emergency affecting Local and
beyond any industrial area of the District. The composition of the Off-site crisis is
covered in. since, the actual offsite plan requires the participation of outside agencies;
this report does not dwell further on the issue. Refer Figure 7-1.

Figure 7-1: Composition of Offsite Crisis Group

District Collector

Off-Site EMP Teams

Each Team has:
1. A Chair Person
2. Secretary
3. Co-ordinator
4. Member

7.8 Offsite Plan Components

Based on the details of the hazard distances of identified containment loss scenarios, the
detailed offsite plan may be drawn up in consultation with the Local Authorities.

7.9 General Safety Practices

7.9.1 Work Permit System

 It is recommended that plot plans of the installation and the operating blocks should be
displayed in the fire and concerned unit control rooms respectively and site of hot jobs
under progress should be indicated on these plot plans with red pins
 No hot/cold work shall be undertaken without a work permit except in the areas
predetermined and designated by the owner-in-charge
 Permit should be issued only for a single shift and its validity should expire at the
termination of the shift. However, where the work has to be continued, the same permit
may be revalidated in the succeeding shift, by authorized person after satisfying the
normal checks
 Equipment or area where work is to be conducted should be inspected to ensure that it is
safe to carry out the work and assess other safety requirements / stipulations Unsafe
conditions for performance of work may arise from surrounding area. It should be
cleaned-up to remove flammable material such as oil, rags, grass etc

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 Other activities (routine / non-routine) being carried out near-by which can create
conditions unsafe for performance of the permit work, should be taken into consideration
and the concerned persons should be alerted accordingly
 Running water hose and portable fire extinguisher are required respectively to flush
/dilute in case of release of any hazardous chemical or to quench sparks and to put out
small fires immediately
 In order to meet any contingency, it should be ensured that the fire water system
including fire water pumps, storage, network etc. is checked and kept ready for
immediate use
 Equipment / Vessel, on which the work permit is being issued, should be completely
isolated from the rest of the plant with which it is connected during normal operation, in
order to ensure that there is no change in the work environment with respect to presence
of toxic / flammable gases, liquids, hazardous chemicals etc. in the course of the work
 Equipment under pressure should be depressurized after isolation. This will be followed
by draining / purging / water flushing etc. as the case may be
 Proper means of exit is required in case of emergencies developed on account of the work
or otherwise. Availability of an alternate route of escape should be considered

7.9.2 Contractor Safety

Duties and responsibilities of the contractor should include the following:
 To implement safe methods and practices, deploy appropriate machinery, tools and
tackles, experienced supervisory personnel and skilled work force etc. required for
execution
 To prepare a comprehensive and documented plan for implementation, monitoring and
reporting of Health, Safety and Environment (HSE) and implement the same after its
approval
 To nominate qualified and trained Safety Engineers / Officers reporting to the Site in
charge, for supervision, co-ordination and, liaison for the implementation of the safety
plan
 To arrange for fire protection equipment as per the advice of owner
 To ensure that its employees have completed appropriate health and safety training as
required by the statute / regulation and also as per requirements of the Owner /Consultant
 To comply with all the security arrangements of owner
 To ensure availability of First Aid boxes and First Aid trained attendant
 To ensure that all incidents including near misses are reported to all concerned
immediately
 To ensure strict compliance with work permit system by carrying out work only with
appropriate work permits and after ensuring that all safety precautions / conditions in the
permit are complied with and closing the same after job completion
 To ensure that the workers likely to be exposed to hazardous chemicals/materials have
access to appropriate Material Safety Data Sheets (MSDS), wherever applicable, and
provide necessary mitigation measures
 To ensure that appropriate warning signboards or tags are displayed
 To ensure that workers have proper training for their job assignments, including use of
appropriate PPE and first aid firefighting equipment

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 To comply with all applicable safety and health standards, rules, regulations and orders
issued by competent authority pertaining to the assigned activities
 To conduct daily inspections to ensure compliance with safety standards, codes,
regulations, rules and orders applicable to the work concerned

7.9.3 Static Electricity

 Ensure no metal objects/appurtenances projecting from roof/shell plates, which will
attract highly charged spots in fuel for dissipation
 Ensure reduced rate of flow initially into tank/vessel until fill point/nozzle is completely
submerged in fluid
 Ensure periodic checking and recording of earthing test for tanks and piping systems are
maintained
 Agitation with air, steam gas, jet nozzle or mechanical mixtures should be avoided
 Ensure no personnel is allowed on tank roof for gauging / sampling during product
transfer unless dip pipes extend to bottom of tanks. Use only mechanical gauges for
ascertaining product transferred during transfer operations otherwise
 Protective bonding is required when fill open containers where the product to be handled
has a flash point below 54.5 oC (130 oF) or, in the case of a higher flash point product,
when it is heated to within 6.0 oC (15 oF) of its flash point. The purpose is to keep the
nozzle and container at the same electrical potential, thus avoiding a possible static spark
in the area of a flammable mixture
 Small containers made up of plastic or other non-conductive materials should not be used
for filling of fuels
 Water washing is safe from a static electricity stand-point. However, there should be no
insulated conductive objects within the tank.

7.9.4 Lightning Protection

 Measures to control fugitive emission from storage tanks should be given special
consideration
 Structures of exceptional vulnerability by reason of explosive or highly flammable
contents need special consideration and every possible protection need to be provided
even against the rare occurrence of a lightning discharge
 A lightning protection system (Conventional Air Terminal System) consists of the
following three basic components - Air terminal, Down conductor and Earth connection
 Non-conducting chimneys whose overall width or diameter at top is up to 1.5m shall be
provided with one down conductor, and chimneys with overall width or diameter at top
more than 1.5m shall be provided with 2 no. down conductors
 Metal stacks shall be properly earthed at the bottom
 Flammable liquids shall be stored in essentially gastight structures
 Openings where flammable concentrations of vapor or gas can escape to the atmosphere
shall be closed or otherwise protected against the entrance of flame
 Structures and all accessories e.g. dip-gauge hatches, vent valves shall be maintained in
good and sound operating conditions

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 Flammable air-vapors mixtures shall be prevented to the greatest possible extent from
accumulating outside storage tanks
 Potential spark-gaps between metallic conductors shall be avoided at points where
flammable vapors may escape or accumulate
 A properly designed / constructed gas tight storage tanks considered to be self-protected
against lightning provided it is properly earthed and bonded. Such a structure may not
require any additional means of lightning protection

7.10 Recommendations
Recommendations are made for different aspects of the project and are given in subsequent
paragraphs.

7.10.1 Storage of Hazardous Chemicals in Bulk

 Attempt should be made to find suitable less hazardous alternate chemicals, to replace the
hazardous chemical. The inventory of all hazardous chemicals for that matter must be
kept as minimum as possible
 The tanks should be located so as not to pose safety problems due to leakage and reaction
with other chemicals stored nearby
 The storage area should be declared as a prohibited area and should be provided with
fencing having at least two exits / “No Smoking” and/or “Prohibited Area” display
boards, as applicable should be provided at site
 The storage tank and foundation should be of suitable material of construction to prevent
corrosion
 The connections and openings to the tank should be as less as possible so that the
possibility of leakage and maintenance hazards is minimized
 Each storage tank should have necessary instruments to monitor its level, pressure and
temperature
 The storage tanks / area should have suitable fire protection and fire fighting facility
 The name of chemical, type of hazard, emergency operational instructions, antidote first
aid etc. should be displayed near each tank
 All cables and electric fittings shall be constructed, installed, protected, operated and
maintained in such a manner so as to prevent risk of open sparking

7.10.2 Storage of Hazardous Chemicals in Drums and other Containers

 The drums should never be filled full with the liquid chemical. There should be sufficient
space to take care of thermal Greenfield
 The drums should preferably be stored in a well ventilated shed (preferably away from
process units) with impermeable floor sloping away from drums
 Periodic site inspection should be carried out to ensure that there is no leakage from any
of the drums

7.10.3 Unloading of Tank Trucks

 Before the tanker enters the industry premises, the tanker is to be inspected for authorized
entry and safe and sound condition of the tanker, its contents and that of the prime mover.
Tankers entering plant are to be fitted with flare arresters on their exhaust

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 Static charge neutralizing at gate entry only

 The quality of the chemical in the tanker should be ascertained before unloading to avoid
contamination of chemical already at storage
 Coupling used for connecting hose to tanker must be leak proof
 For flammable chemicals, the tanker and the hose are to be properly earthed before
starting unloading operation
 Unloading should be done under personal supervision of responsible staff authorized by
the management
 Provision of sample quantity of water / neutralizing medium to take care of leakage
/spillage must be made. Also steam and inert gas hose stations must be available at
unloading point
 Fire alarm and fire fighting facility commensurate with the chemical should be provided
at the unloading point

7.10.4 Hazardous Waste Transport

The occupier of hazardous substance shall prepare six copies of the manifest (transporting
documents) in Form 9 comprising of colour code indicated below (all six copies to be signed
by the transporter):
 Copy 1 (White): to be forwarded by the occupier to the State Pollution Control Board or
Committee
 Copy 2 (Yellow): to be retained by the occupier after taking signature on it from the
transporter and rest of the four copies to be carried by the transporter
 Copy 3 (Pink): to be retained by the operator of the facility after signature
 Copy 4 (orange): to be returned to the transporter by the operator of facility after
accepting waste
 Copy 5 (Green): to be returned by the operator of the facility to State Pollution Control
 Board / Committee after treatment and disposal of wastes.
 Copy 6 (Blue): to be returned by the operator of the facility to the occupier after
treatment and disposal of wastes
The occupier shall forward copy number 1 (white) to the State Pollution Control Board or
Committee and in case the hazardous waste is likely to be transported through any transit
State, the occupier shall prepare an additional copy each for such State and forward the same
to the concerned State Pollution Control Board or Committee before he hands over the
hazardous waste to the transporter. No transporter shall accept hazardous wastes from an
occupier for transport unless it is accompanied by copy numbers 2 to 5 of the manifest. The
transporter shall return copy number 2 (yellow) of the manifest signed with date to the
occupier as token of receipt of the other four copies of the manifest and retain the remaining
four copies to be carried and handed over to respective agencies as specified in sub-rule (4).

7.11 Public Consultation

Public consultation

During Public hearing the following point discussed

Sr. Issue Raised Response

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No
1. When this air pollution industry what Care to be taken for controls of noise level are
measures will be taken for control of included in EIA report, PPEs will be provided
noise during crushing operations. to the workers.
2. As per the Executive summary of the Figure showing in executive summary for the
project, the water requirement will be water requirement is a typographical mistake;
200 CMD but considering the drought the actual requirement of water is 97 CMD.
prone area. The proposed project is sister concerned of
M/s Nath Pulp and paper mills ltd to which
water has been already been sanctioned by the
irrigation department and mostly the water
from Jaikwadi Dam will be used with
agreement between both the companies and
priority will not be given for the ground
water.
3. About noise monitoring pointed out that Noise monitoring is carried out 6 different
noise level is more than the prescribed places as per TOR and the control measures
limit at some places are included in the report for reducing the
noise level.

After Public hearing noise level monitored 6

different places as per TOR, and we found
noise level was within the prescribed limit.
Incorporate the noise monitoring report in
Chapter 3.

Total number of public participants present for 46

public hearing

In order to ascertain the concern of the local persons who have plausible stake in the
environmental impact of this project, the proponents though it fit to interview some people as
sample survey basis. These interviews were oral and informal. This was not meeting any
statutory requirement or a mechanical formality. Proponent really wanted to know as to whether
this project is a welcome addition in the minds of surrounding people.

 There is a constant rapport, open corridors for discussion and transparency in working.
 No odor or noise nuisance is felt.
 It is however, necessary to see that no water pollution is created by this industry, for
which the proposed arrangement appears to be satisfactory.
 Sons of the soil should get preference in employment.

The local people and proponents are comfortable with each other

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7.12 Project Specific Study

Risk Analysis report on Rama Paper Group’s Linear Alkyl Benzene Sulphonic Acid
(LABSA) 50MT/Day and Single Super Phosphate (SSP) 400MT/Day

Rama Paper group is proposing to set up a manufacturing unit, with two plants. One for
manufacturing 50 MT per month of Linear Alky Benzene Sulphonic Acid (LBSA) and
another plant for manufacturing Single Super Phosphate 400 MT per month. 80% diluted
Sulphuric Acid is by product from LBSA plant.
Sr. No. Product Quantity Quantity MT/year
MT/month
1 Linear Alkyl Benzene
1500 18000
Sulphonic Acid (LABSA)
2 Diluted Sulphuric Acid
1327.50 15930
80%
3 Single Super Phosphate 12000 144,000
(SSP)

Raw Material requirements are Linear Alkyl Benzene and 98% Sulphuric Acid for LBSA
production and Indian Rock Phosphate (33% P2O5) and Sulphuric Acid for SSP production
Brief Process Description for LABSA:
Linear Alkyl Benzene (LAB) is stored in 2 vertical storage tanks of capacity 200m3
capacities. Each tank is provided with Level indicator with low level alarm. LAB is pumped
to the Sulphonator through a measuring overhead vessel. This is provided with overflow line
to ensure exact required quantity is charged to the sulphonator.
Sulphuric acid is stored in underground tank of 200 MT capacities. Sulphuric acid is pumped
to three overhead batch tanks and added sequentially.
Agitation/ mixing is started by starting an external circulation pump. Then 98% Sulphuric
acid added slowly over a period of 6 to7 hours controlling the temperature between 55 to 60
deg C by both cooling water circulation through reactor jacket and by controlling rate of
Sulphuric acid addition.
There is TI and TIA alarm provided at the circulation pump suction. There is a provision of
pump running and for stopping/starting the pump from the control room.
After complete addition and ensuring the reaction is complete the reaction mass is diluted by
controlled addition of water, under agitation to control reactor temperature within 55 to 60
deg C.

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Then Reactor mass is transferred to settling tank for separation of LBSA and 80 % spent acid
layers.
LABSA is transferred to LABSA product tank and spent acid layer to spent acid storage
tanks.
Storage Details for Raw Materials and Finished Products.

Capacity
Sr No Material Number MOC
MT
1 LAB 200 2 MS
2 LABS 50 2 MS
3 H2 SO4 (98%) 200 1 MS
4 H2 SO4 (80%) 50 1 MS
5 H2 SO4 (70%) 100 1 MS (Rubber lined)

Areas of Concern and Mitigation measures:

In this plant, Sulphonation reaction section is the only area of serious area of concern from
the Risk assessment and Hazard control point of view.

As this Sulphonation reaction is inherently a dangerous process. The reaction is exothermic

and rate of reaction increase with temperature. There is possibility of runaway reaction
leading to explosion under any of the following conditions
1. Uncontrolled reactant addition,
2. Accumulation of un reacted Sulphuric Acid,
3. Failure of agitation and
4. failure of Cooling medium
Sulphonator, in particular needs to have all the instrumentation, interlocks and safety devices
installed to minimize and desirably totally eliminate occurrence of abnormal conditions.

One of the recommended tools to identify risks, potentially hazardous situations is by

systematic HAZOP studies.

And it is necessary to do this, in the early design stage to avoid modifications and additional
expenditure. One of the recommended tools to identify risks, potentially hazardous
situations is by systematic HAZOP studies.

And it is necessary to do this, in the early design stage to avoid modifications and additional
expenditure.

HAZOP study will reveal

1. Violations of operating conditions (from the normal operating procedures and conditions)
which can lead to hazardous situation.

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2. HAZOP study will recommend modification of process, installing proper

instrumentation, alarms and interlocks to minimize the risk.
3. It will examine whether the built in instrumentation, alarms, interlocks and Safety devices
are adequate or not.

Mitigation Measures:

1. It is strongly recommended that formal HAZOP study should be carried out for the entire
process. And it should be ensured that all the recommendations of the study with respect
to installation of instrumentation controls, alarms and interlocks are installed.
2. As it may come out of HAZOP study, interlock to stop addition in case of temp. rise,
Cooling water failure, and agitation pump tripping will have to be provided.
3. Operating Manual prepared should specifically include range of critical parameters, like
rate of addition of Sulphuric Acid, operating temperature range, actions to be taken in
case of agitation failure and cooling medium failure etc.
4. Emergency shutdown procedure should be displayed prominently in the language
understood by the operators.
5. It must be ensured that standard Operating procedure laid down in the manual is strictly
adhered to. No variation in this should be permitted.
6. Operators should be trained and be made aware of hazard and eminent danger in case
violation of standard operating procedures.

Storage tank area is not area of concern as both LAB (Flash point 140 deg C) and LBSA are
not flammable and Sulphuric acid storage is under ground and only hazard involved of
leakage through flange or gland leaks can be dealt with standard maintenance and operation
precautions.

It was confirmed by the consultants that necessary safety measures will be incorporated
during detail designing with respect to plant layout and storage tank layout for Sulphuric
acid, LAB, LABS and 70 and 80 % sulphuric acid, with properly designed dyke walls for
over ground storage tanks.

Other Mitigation Measures

1. The project is in the design and detailing stage.

2. Adequate Fire fighting system will be designed.
3. This unit is registered under Factories Act and is bounded by State Factory Rules and
accordingly all statutory requirements will be fulfilled. Moreover, disciplined approach is
natural to this industry.
Consultant and Director of the company have committed the following
1. Safety and Occupational Health will be dealt carefully.
2. Safety policy will be in place.

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3. Consulting physician shall be retained to attend the factory.

4. Personal protection equipments will be provided and use will be insisted.
5. First aid trained and Fire fighting trained person will be available in every shift.
6. Safety Officer shall be appointed and will be competent person.
7. Fire fighting system is kept as per norms of Insurance Company and CIF.
8. DMP (Disaster Management Plan) and off-site emergency plan shall be in place.
Accordingly.

7.12 Material Safety Data Sheet of Sulphuric acid

7.12.1General description

 Sulfuric acid is a colorless oily liquid

 It is soluble in water with release of heat.
 It is corrosive to metals and tissue.
 It is corrosive to metals and tissue.
 It will char wood and most other organic matter on contact, but is unlikely to cause a
fire.
 Density 15 lb/gal
 Long term exposure to low concentrations or short term exposure to high
concentrations can result in adverse health effect from inhalation.
 It is used to make fertilizers and other chemicals, in petroleum refining, in iron and
steel production, and for many other uses.
 Rate of onset: Immediate
 Persistence: Hours, days
 Odor threshold
 Source/use/other hazard: Battery/dyes/paper/glue/metals industries; volcanic gas;
toxic fumes when heated.

NFPA Diamond

Red 0- will not burn under typical fire conditions

Blue 3 – can cause serious or permanent injury

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Yellow 2 – Readily undergoes violent chemical changes at

elevated temperature and pressures.

Special W- reacts violently or explosively with water

7.12.2Physical properties

 Chemical Formula: H2SO4

 Flash Point: data unavailable
 Lower explosive limit(LEL):data unavailable
 Upper explosive Limit(UEL): data unavailable
 Auto ignition Temperature: Not flammable (USCG, 1999)
 Melting Point: 50.650F (EPA, 1998)
 Vapor Pressure: 1 mm Hg at 294.80F (EPA, 1998)
 Vapor Density (Relative to Air): 3.4 (EPA, 1998)
 Specific Gravity: 1.841 (EPA, 1998)
 Boiling Point: 5540F at 760.0mm Hg (EPA, 1998)
 Molecular Weight: 98.08 (EPA, 1998)
 Water solubility: Miscible (NIOSH,2003)
 IDLH: 15mg/m3 (NIOSH, 2003)

Reactivity Alerts

 Strong oxidizing agent

 Known catalytic activity
 Water-reactive

Air & Water Reactions

 Reaction with water is negligible unless acid strength is above 80-90% then heat
from hydrolysis is extreme, may cause severe burns (Merck, 11th ed.1989).
 During sulfonation of mononitrobenzene by fuming sulfuric acid, a leak from an
internal cooling coil permitted water to enter the reaction tank and a violent
eruption occurred due to the heat of solution (MCA Case History 944 1963).

Fire Hazard

 It is highly reactive and capable of igniting finely-divided combustible materials on

contact.
 When heated, it emits highly toxic fumes.

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 Avoid heat; water and organic materials

 Sulfuric acid is explosive or incompatible with an enormous array of substances.
 Can undergo violent chemical change at elevated temperatures and pressure.
 May react violently with water.
 When heated, it emits highly toxic fumes.
 Hazardous polymerization may not occur. (EPA 1998)

Health Hazard

 Corrosive to all body tissues.

 Inhalation of vapor may cause serious lung damage.
 Contact with eyes may result in total loss of vision
 Skin contact may produce severe necrosis
 Fatal amount for adult: between 1 teaspoonful and one-half ounce of the
concentrated chemical
 Even a few drops may be fetal if the acid gains access to the trachea.
 Chronic exposure may cause tracheobronchitis, stomatitis, conjunctivitis, and
gastritis.
 Gastric perforation and peritonitis may occur and may be followed by circulatory
collapse.
 Circulatory shock is often the immediate cause of death.
 Those with chronic respiratory, gastrointestinal, or nervous diseases and any eye
and skin diseases are at greater risk (EPA,1998)

Reactivity Profile

 Sulfuric acid is a strong acid.

 Reacts violently with bromine pentafluoride (Mellor 2 Supp. 1:172 1956)
 Exploded with para-nitrotoluene at 800c (Chem.Eng.News 27:2504)
 An explosion occurred when concentrated sulfuric acid was mixed with crystalline
potassium permanganate in a vessel containing moisture and Manganese heptoxide
was formed, which explodes at 700C (Delhez 1967).
 A mixture of acrylonitrile with concentrated sulfuric acid must be kept well chilled
otherwise a vigorous exothermic reaction occurs. (Chem. Safety Data Sheet SD-
31:8.1949).
 Mixing sulfuric acid (96%) in equal portions with any of the following substances
in a closed container caused the temperature and pressure to increase: acetonitrile,
acrolein, 2-aminoethanol, ammonium hydroxide (28%), aniline, n-butyraldehyde,
chlorosulfonic acid, ethylene diamine, epichlorohydrin, ethylene cyanohydrin,
hydrochloric acid (36%), hydrofluoric acid (48.7%), propiolactone, propylene
oxide, sodium hydroxide, styrene monomer (NFPA 1991)

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 Sulfuric acid (concentrated) is extremely hazardous in contact with carbides,

bromates, chlorates, fulminates, picrates and powdered metals (Haz.Chem. Data
1966)
 Allyl chloride may polymerize violently under conditions involving an acid
catalyst, such as sulfuric acid (Ventrone 1971).
 React exothermally with sodium hypochlorite to produce chlorine gas.
 Mixing chlorosulfuric acid and 98% sulfuric acid may evolve HCl (Subref: Anon.
Loss Prev. Bull. 1977, (013), 2-3)
 Zinc iodide reacts violently with H2SO4 (Pascal, 1962, Vol.5,168)

Belongs to the following reactive groups

 Acids, Strong Oxidizing

Potentially incomplete absorbents

 Cellulose-Based Absorbents
 Expanded Polymeric Absorbents

Isolation & Evacuation

 As an immediate precautionary measure, isolate spill or leak area in all directions

for at least 50 meters (150 feet) for liquids and at least 25 meters (75 feet) for
solids
 In case of spill, increase, in the downwind direction, as necessary, the isolation
distance shown above.
 If tank, rail car or tank truck is involved in a fire, isolate for 800 meters (1/2 mile)
in all directions; also, consider initial evacuation for 800 meters (1/2 mile) in all
directions. (ERG,2012)

Firefighting

 Fight fire from safe distance or from protected location

 Use care as water applied directly to this acid result in evolution of heat and
causes spattering.
 Cool containers that are exposed to flames with streams of water until fire is out.
 Wear positive pressure breathing apparatus and special protective clothing.
 Not flammable.
 For small fires use dry chemical or carbon dioxide.
 Use water on combustibles burning in vicinity of this material.
 For large fires flood fire area with water from a distance.
 Do not get solid streams of water on material.

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 Move container from area if you can do so without risk.(EPA, 1998)

Non-Fire Response

 Fully encapsulating, vapor protective clothing should be worn for spills and
leaks with no fire.
 Do not touch damaged containers or spilled material unless wearing appropriate
protective clothing.
 Stop leak if you can do it without risk.
 Use water spray to reduce vapors; do not put water directly on leak, spill area or
inside container.
 Keep combustible (wood, paper, oil etc.) away from spilled material.
 Increase of small spill, cover with dry earth, dry sand or other non-combustible
material followed with plastic sheet to minimize spreading or contact with rain.
 Use clean non-sparking tools to collect material and place it into loosely covered
plastic containers for later disposal.
 Prevent entry into waterways, sewers, basements or confined areas (ERG, 2012)

Protective Clothing

 Skin: wear appropriate personal protective clothing to prevent skin contact.

 Eyes: wear appropriate eye protection to prevent eye contact.
 Wash skin: the worker should immediately wash the skin when it becomes
contaminated.
 Remove: work clothing that becomes wet or significantly contaminated should be
removed and replaced.
 Change: no recommendation is made specifying the need for the worker to
change clothing after the work shift.
 Provide: eyewash fountains should be provided (when concentration is > 1%) in
areas where there is any possibility that workers could be exposed to the
substance’ this is irrespective of the recommendation involving the wearing of
eye protection. Facilities for quickly drenching the body should be provided
(when concentration is > 1%) within the immediate work area for emergency use
where there is a possibility of Exposure.

First Aid

 Caution: Sulfuric acid is extremely corrosive. Caution is advised.

 Signs and symptoms of Acute Sulfuric acid Exposure; Sign and symptoms of
acute ingestion of sulfuric acid may be severe and include salivation, intense
thirst, difficulty in swallowing, pain and shock. Oral, esophageal and stomach
burns are common. Vomits generally has a coffee-ground appearance. The

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potential for circulatory collapse is high following ingestion of sulfuric acid.

Acute inhalation exposure may result in sneezing, hoarseness, chocking,
laryngitis, dyspnea (shortness of breath), respiratory tract irritation, and chest pain.
Bleeding of nose and gums, ulceration of the nasal and oral mucosa, pulmonary
edema, chronic bronchitis and pneumonia may also occur. If the eyes have come
in contact with sulfuric acid, irritation, pain swelling, corneal erosion and
blindness may result. Dermal exposure may result in severe burns, pain and
dermatitis (red, inflamed skin).
 Emergency Life-Support Procedures: Acute exposure to sulfuric acid may require
decontamination and life support for the victims. Emergency personnel should
wear protective clothing appropriate to the type and degree of contamination. Air
purifying or supplied- air respiratory equipment should also be worn, as necessary.
Rescue vehicles should carry supplies such as plastic sheeting and disposable
plastic bags to assist in preventing spread of contamination.
 Inhalation Exposure
1. Move victims to fresh air. Emergency personnel should avoid self-exposure to
sulfuric acid.
2. Evaluate vital signs including pulse and respiratory rate, and note any trauma. If
no pulse is detected, provide CPR. If not breathing, provide artificial respiration. If
breathing is labored, administer oxygen or other respiratory support.
3. Obtain authorization and /or further instructions from the local hospital for
administration of an antidote or performance of other invasive procedures.
4. Rush to a health care facility.
 Dermal/Eye Exposure
1. Remove victims from exposure. Emergency personnel should avoid self-
exposure to sulfuric acid.
2. Evaluate vital signs including pulse and respiratory rate, and note any trauma. If
no pulse is detected, provided CPR. If not breathing, provide artificial respiration.
If breathing is labored, administer oxygen or other respiratory support.
3. Remove contaminated clothing as soon as possible.
4. If eye exposure has occurred, eyes must be flushed with lukewarm water for at
least 15 minutes.
5. Wash exposed skin areas thoroughly with soap and water.
6. Obtain authorization or further instructions from the local hospital for
administration of an antidote or performance of other invasive procedures.
7. Rush to a health care facility.
 Ingestion Exposure
1. Evaluate vital signs including pulse and respiratory rate, and note any trauma. If
no pulse is detected, provide CPR. If not breathing, provide artificial respiration. If
breathing is labored, administer oxygen or other respiratory support.

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2. Rinse mouth with large amounts of water. Instruct victims not to swallow the
water.
3. Do not induce vomiting or attempt to neutralize
4. Obtains authorization or further instructions from the local hospital for
administration of an antidote or performance of other invasive procedures.
5. Activated charcoal is of no value.
6. Give the victims water or milk: children up to 1 year old, 125 mL (4 oz or ½
cup); children 1 to 12 years old, 200 mL (6 oz or ¾ cup); adults, 250 Ml (8 oz or 1
cup). Water or milk should be given only if victims are conscious and alert.
7. Rush to a health care facility.(EPA, 1998)

7.13. Material Safety Data Sheet of Linear Alkyl Benzene

7.13.1General description

 Linear alkyl benzene is a family of organic compounds with the formula

C6H5CnH2n+1
 Typically lies between 10 and 16, although generally supplied as a tighter cut,
such as C12-C15, C12-C13 and C10-C13 for detergent use.
 The CnH2n+1 chain are unbranched. They are sometimes called LABs
 They are mainly produced as intermediate in the production of surfactants, for use
in detergents.
 Since the 1960s, LAB has emerged as the dominant precursor of biodegradable
detergents.

NFPA Diamond

Red 1- Flammable

Blue1-Harmful on contact with skin or ingestion

Yellow 0- Stable

7.13.2 Physical properties

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 Chemical Formula: C6H5CHR1R2 where R1=CnH2n+1 and R2 = CmH2m+1 .m,n are

integers m≥ 1 (typically 10-16)
 Flash Point: 2840F
 Lower Explosive Limit (LEL): data unavailable
 Upper Explosive Limit (UEL):data unavailable
 Auto ignition Temperature: data unavailable
 Melting Point< -940F
 Vapor Pressure: 0.013h Pa at 770F
 Vapor Density (Relative to Air): 8.4
 Specific Gravity: 0.858-0.868
 Boiling Point: 532.4-597.20F
 Molecular Weight: 239-245
 Water Solubility: Slightly Soluble\
 IDLH: data unavailable

Reactivity Alerts

 Stable
 Incompatible with strong oxidizers and no dangerous polymerization.

Fire Hazard

 Combustible products – CO & co2

Health Hazard

 Product irritates eyes and skin

 Acute toxicity data
 Chronic effects cause mil irritation
 May cause mild skin irritation.
 Not a carcinogen, mutagenic
 Not applicable for toxicokinetics, metabolism, distribution.

Reactivity Profile

 Prolonged exposure of containers or tank cars to heat or fire may cause the material
to expand with possible container rupture.
 Very dangerous fire hazard when exposed to oxidizers
 Thermal decomposition generates carbon monoxide and carbon dioxide.
 No dangerous polymerization.

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Firefighting

 Suitable extinguishers media: Foam, Dry Chemical powder, co2

 Cool containers with water spray.
 Extinguishing media to be avoided: water
 Do not empty into drains
 When burning, it emits carbon monoxide, carbon dioxide and irritant fumes.
 Containers with the substance exposed to excessive heat may explode.
 Wear full protective fire- resistant clothing and self contained breathing apparatus.

Accident Release Measures

 Wear protective clothing and equipment.

 Isolate hazard area.
 Evacuate all unauthorized personnel not participating in rescue operations from the
area.
 Avoid entry into danger area.
 Remove all possible sources of ignition.
 Stop traffic and switch off the motors of the engines.
 Do not smoke and do not handle with naked flame.
 Use explosion-proof lamps and non-sparking flame.
 Use explosion-proof lamps and non-sparking tools.
 Avoid contact with the substances.
 Dike flow of spilled material using soil of sandbags to minimize contamination of
drain surface and ground waters.

Handling and Storage

 Information for safe handling-observe all fire-fighting measures (no smoking, do not
handle with naked flame and remove all possible sources of ignition). Take
precautionary measures against static discharges. Wear recommended personal
protective equipment and observe instructions to prevent possible contact of
substance with skin and eyes and inhalation.
 Information for storage-store rooms should meet the requirements for the fire safety
of constructions and electrical facilities and should be in conformity with valid
regulations. Store in cool, well-ventilated place with effective exhaust, away from
heat and all sources of ignition. Take precautionary measures against static
discharges.
 Information for specific use- Detergent intermediate-follow bulk handling and
storage procedures as noted above.

First Aid
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 Immediate medical attention is required after inhalation or after swallowing

 In case of health troubles or doubts, seek medical advice immediately
 Inhalation- Remove to fresh air, if not breathing, give artificial respiration. If
breathing is difficult, give oxygen. Get medical attention immediately
 Skin contact: wash skin with water upon contact. Remove contaminated clothing. If
irritation persists, get medical attention. Wash clothing before reuse.
 Eye contact –In case of contact, immediately flush eyes with plenty of water for at
least 15 minutes. Get medical attention.
 Swallowing- if swallowed, do not induce vomiting, get medical attention. Never
give anything by mouth to an unconscious person

Occupational Health: in process there is high noise, high heat stress and low level illumination
exposure to workers.

Manual material handling only the causes of musculo-sketal disorders (MSD) backache,
pain in minor and major joints, fatigue etc. following measures have been taken to avoid
above mentioned ill health effect to workers.

 Below 25 kgs weight will be handled by a worker if required to do so.

 Material handling lorry-cart, drum handling trolly, fork lift, stacker, etc. will be
used for material handling.
 Training will be carried out for manual material handling.
 Ergonomics study will be carried out before commissioning of the plant and
correct material flow, process flow of work place will be designed.

Following activities will be carried out for occupational health of the workers.

 Treatment part (OPD) for both company and contractor employees

 Occupational related problems will be studded like ergonomic issues and control
measures prevention part-pre medical examination and periodical medical
examination for operators, helpers, chemists.
 Profile active (Health Awareness programme)

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Table 7.3: Occupational health impact on employees, control measures, action plan if
accident occurs

S Chemical Occupational health Measures to keep EMP for STEL & IDLH
r. impact on employees exposure below
N TLV/PEL
o.
1 Sulfuric Prolonged or Facilities storing or Clean up spills immediately,
Acid repeated skin contact utilizing this material observing precautions in the
may cause dermatitis. should be equipped with Protective Equipment section.
Prolonged or an eyewash facility and a Carefully scoop up and place into
repeated inhalation safety shower. Use appropriate disposal container.
may cause adequate general or local Provide ventilation. Do not get
nosebleeds, nasal exhaust ventilation to water inside containers. Cover with
congestion, erosion keep airborne dry earth, dry sand, or other non-
of the teeth, concentrations below the combustible material followed with
perforation of the permissible exposure plastic sheet to minimize spreading
nasal septum, chest limits. Use a corrosion and contact with water.
pain and bronchitis resistant ventilation
system.
2 LAB/ Route of entry: Provide adequate Person-related safety precautions
. LABSA Those with history of ventilation when using Wear protective clothing and
lung diseases, or skin the material and follow equipment. Isolate hazard area.
problems may be the principals of good Evacuate all unauthorized personnel
more susceptible to hygiene to control not participating in rescue
the effect of this personal exposure. operations form the area. Avoid
material. entry into danger area. Remove all
possible sources of ignition. Stop
traffic and switch off the motors of
the engines. Do not smoke and do
not handle with naked flame. Use
explosion-proof lamps and non-
sparking tools. Avoid contact with
the substance.
Precautions for protection of the
environment
Prevent from further leaks of
substance. Dike flow of spilled
material using soil or sandbags to
minimize contamination of drains,
surface and ground waters.
Recommended methods for cleaning
and disposal
Soak up residues with compatible
porous material and forward for
disposal in closed containers.
Dispose off under valid legal waste
regulations

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7.14 EHS POLICY

OCCUPATIONAL SAFETY, HEALTH & ENVIRONMENT PROTECTION POLICY

Factory proposed to be declare their Safety, Health Environment policy. The declaration is as
under:

We at M/s Rama Pulp and Paper Ltd. are committed to create and maintaining Safe and Healthy
work place with environment friendly operations in our organization. We will develop and
implement our occupational Health, Safety and Environment. Management system confirming to
National and Environment Management System will be integral part of our work culture.

Occupational health, Safety and Environment will be integrated part of our decision and
activities. Will continually review and update performance on this front:

Factory shall strive to achieve objectives by:

 Well-defined organization set up for implementation of the Health, Safety and Environment
Policy implementation.

 Encouraging participation of all employees, contractor employees in Health, Safety and

Environment activities.

 Ensuring competence by imparting adequate effective Training and Education to all employees.

 Evaluation of Health, Safety and Environment performance and communicate to all.

 Health, Safety and Environment performance will form as an integral part of Personal
Assessment Pro-forma for all employees.

 Compliance of all statutory requirements.

 Periodic Risk Assessment and Safety Audits will be carried out to ensure effectiveness of Health,
Safety and Environment systems and up-gradation.

 Work zone monitoring will be carried out periodically to ensure safe work environment and
conservation of Natural Resources.

 Short resume will be mentioned about Health, Safety and Environment activities in the
company’s Annual Report.

Declared on: Occupier

Review on

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32 sd engineering services pvt ltd, Aurangabad