26072016B92UY7I2Annexure documentofRiskAssessment PDF

Annexure 3: Document of Risk
Assessment
EIA/EMP & RA/DMP REPORT FOR ESTABLISHMENT OF 5
LAKH KLPA CAPACITY PAINT & RESINS / WATER BASED
POLYMERS MANUFACTURING PLANT AT VISHAKHAPATNAM
M/S. ASIAN PAINTS LIMITED DISTRICT, ANDHRA PRADESH ADDITIONAL STUDIES
7.2 Risk Assessment Study / Hazard Identification and Consequence Analysis
Hazard analysis for estimation damage distances for failure scenarios is carried out using DNV
PHAST software.
7.2.1 About PHAST Software
The consequence analysis for the modeled scenarios has been done using DNV’s software PHAST
(Process Hazard Analysis Software Tool) which allows assessment of situations which present
potential hazards to life, property and the environment, and to quantify their severity. PHAST
examines the progress of a potential incident from the initial release to far-field dispersion
including modelling of pool spreading and evaporation, and flammable and toxic effects. It is
recommended for use by the Ministry of Environment & Forests per its EIA Guidelines, dated
January 2001.
 ‘PHAST’ Micro version 6.53.1 (DNV Technica, UK): To calculate consequence effect of toxic
and flammable chemicals for a storage vessels.
 ‘PHAST’ Pro (DNV Technica, UK): To calculate consequence effect of toxic and flammable
chemicals for a long pipeline.
 ‘PHAST’ Risk (DNV Technica, UK): To calculate the impact of the release of a toxic or
flammable chemicals on the populations. The results are presented in variety forms viz. F-N
curve for societal risk, individual risk, ranking tables for the contribution of each events,
overall rate of death and other summary societal risk measures.
PHAST Professional’s sophisticated modeling calculates distances effect produced by hazardous

events. With this information, you can evaluate the need for mitigating measures such as changes
in design, operation or response. PHAST software can be used to model a proposed facility or
operational change to ease the selection of the most effective solutions. With PHAST Professional,
you can define special events, model a leak of a mixture of materials, model the change in a leak
over time, and investigate the details of behavior with special stand-alone models and much,
much more.
PHAST is integrated into safety and meets regulatory requirements. It uses unified dispersion
modeling to calculate the results of the release of material into atmosphere
The salient features of this package:
1. It gives the consequence results in terms of – Flammable, Toxic and Explosion effects.
2. Flammable parameters covered under this package is-
 Defines the LEL and UEL zone

 Jet fire and pool fire scenario along with their respective effect zones (risk contour).
 Flash fire and fire ball envelope
3. Toxic parameters-
 Cloud concentration at user defined time as well as location

 Categorize the toxic results in terms of ERPG, IDLH and STEL values.
 Summarize results in terms of equivalent toxic dose along with effect zones.
4. Explosion parameters-
 Categorize the explosion effects in terms of overpressures levels along with distance
covered.
 BLEVE (Boiling Liquid Expanding Vapor Explosion)
KADAM ENVIRONMENTAL CONSULTANTS | JULY 2016 230

7.2.2 Hazard Identification
The project description, and other project related data provided by the client have been
comprehensively reviewed to identify the hazardous operations. Also, the information on the
hazardous properties (MSDS) of all the chemicals handled at the site has been reviewed to identify
the hazards associated with the same.
 Raw material powder handling and storage

 Raw materials are received as fine powders packed in jumbo bags or special containers.
Unloading, handling and stacking operations are carried out using EOT cranes, pallets and
forklifts.
 No grinding operation is carried out in the facility.
 During normal operation, there will not be any significant dust generation.
 The materials are not combustible and there is no likelihood of dust explosion.
 The materials do not contain any significant amount of silica.
 The powder from bags is emptied into hopper from which it is conveyed pneumatically by
blower to storage silo in closed system. As the feed hopper will be under slight negative
pressure of blower suction, very little dust is expected to be released at the point of discharge
from bags. The following provisions will be made to prevent/ minimize occupational exposure
to dust.
 Dust extraction system with bag filters.
 Suitable PPE for respiratory protection designed for proper fit and comfort.
 Necessary kits and trained personnel for handling any accidental spillage of fine powder due
to damage of bag while handling.
Storage of some of the hazardous material at the site can lead to uncontrolled release of
hazardous material causing hazard. On the basis of this, the important hazards that can lead to
accident in the proposed project are described in Table 7-2.
Table 7-2: Important Hazardous Events

Type of Event Explanation
Boiling Liquid Evaporating Vapor Explosion; may happen due to catastrophic failure
BLEVE of refrigerated or pressurized gases or liquids stored above their boiling points,
followed by early ignition of the same, typically leading to a fire ball
Is the same as detonation but with reaction occurring at less than sonic velocity and
Deflagration
initiation of the reaction at lower energy levels
A propagating chemical reaction of a substance in which the reaction front advances
Detonation
in the unreacted substance at or greater than sonic velocity in the unreacted material
Explosion A release of large amount of energy that form a blast wave
Fire Fire
Fireball The burning of a flammable gas cloud on being immediately ignited at the edge
before forming a flammable/explosive mixture.
Flash Fire A flammable gas release gets ignited at the farthest edge resulting in flash-back fire
A jet fire occurs when flammable gas releases from the pipeline (or hole) and the
Jet Fire released gas ignites immediately. Damage distance depends on the operating
pressure and the diameter of the hole or opening flow rate.
Pool fire is a turbulent diffusion fire burning above a horizontal pool of vaporizing
Pool Fire
hydrocarbon fuel, where the fuel has zero or low initial momentum

Type of Event Explanation

‘Loss of containment’. Release of fluid or gas to the surroundings from unit’s own
Spill Release
equipment / tanks causing (potential) pollution and / or risk of explosion and / or fire
Breakage or fatigue failures (mostly failures caused by weather but not necessarily)
Structural Damage
of structural support and direct structural failures
Vapor Cloud Explosion resulting from vapor clouds formed from flashing liquids or non-flashing
Explosion liquids and gases
7.2.3 Hazard and Damage Assessment
Toxic, flammable and explosive substances released from sources of storage as a result of failures
or catastrophes, can cause losses in the surrounding area in the form of:
 Fires, fireballs, and flash back fires, resulting in a heat wave (radiation), or
 Explosions (Vapors Cloud Explosions) resulting in blast waves (overpressure).
Consequences of Fire/Heat Wave
The effect of thermal radiation on people is mainly a function of intensity of radiation and
exposure time. The effect is expressed in term of the probability of death and different degree of
burn. The consequence effects studied to assess the impact of the events on the receptors are
provided in Table 7-3.
Table 7-3: Damage due to Radiation Intensity

Radiation (kW/m2) Damage to Equipment Damage to People
Causes pain if duration is longer than 20 sec.
4.0 -
But blistering is unlikely.
Minimum energy to ignite wood
1% lethality in one minute. First degree
12.5 with a flame; melts plastic
burns in 10 sec.
tubing.
100% lethality in 1 min.
37.5 Severe damage to plant 50% lethality in 20 sec.
1% lethality in 10 sec.
Consequences of Overpressure
The effects of the shock wave vary depending on the characteristics of the material, the quantity
involved and the degree of confinement of the vapor cloud. The peak pressures in an explosion
therefore vary between a slight over-pressure and a few hundred kilopascals (kPa). Whereas
dwelling are demolished and windows and doors broken at overpressures as low as 0.03- 0.1 bar.
Direct injury to people occurs at greater pressures. The pressure of the shock wave decreases
rapidly with the increase in distance from the source of the explosion. The overpressure damage is
shown in Table 7-4.
Table 7-4: Overpressure Damage

Overpressure (bar) Damage
0.027 Limited minor structural damage

0.136 to 0.204 Concrete of cinder brick walls, not reinforced, shattered

Overpressure (bar) Damage
0.2068 Heavy machines (3,000 lb) in industrial building suffered little damage; steel
frame building distorted and pulled away from foundations.
Source: CCPS Consequence Analysis of Chemical Release
Raw Material Powder Handling and Storage
Raw materials will be received as fine powders packed in jumbo bags or special containers.
Unloading, handling and stacking operations will be carried out using EOT cranes, pallets and
forklifts.
 No grinding operation will be carried out in the facility.

 During normal operation, there will not be any significant dust generation.
 The materials are not combustible and there is no likelihood of dust explosion.
 The materials do not contain any significant amount of silica.
 The powder from bags is emptied into hopper from which it is conveyed pneumatically by
blower to storage silo in closed system. As the feed hopper will be under slight negative
pressure of blower suction, very little dust is expected to be released at the point of discharge
from bags. The following provisions will be made to prevent/ minimize occupational exposure
to dust.
 Dust extraction system with bag filters.
 Suitable PPE for respiratory protection designed for proper fit and comfort.
 Necessary kits and trained personnel for handling any accidental spillage of fine powder due
to damage of bag while handling.
Polymerization Reactors
The emulsion required for paint manufacture is prepared in batch polymerization reactors.
Monomers, catalyst and other chemicals are added as per the recipe to produce emulsion in
aqueous phase. The polymerization reaction is exothermic and cooling water is used to control
reactor temperature. The reaction is carried out at atmospheric pressure.
The following provisions will be made to ensure safety in polymerization reaction system.
 Load cells for reactor and pre-emulsifier vessels to control the quantities of chemicals added
and prevent overfilling
 DCS to ensure proper operation sequence of reactor system
 Alarms and shutdown interlocks for high pressure and high temperature in reactor using
multiple instruments
 Rupture disk for over-pressure protection of reactor with safe arrangement to collect vapour
released from rupture disk
 System for safe collection of any spillage in pit for transfer to ETP
Water based paint plant
Dispersion and mixing operations will be carried out in closed system at atmospheric pressure.
Packing will be done by automatic machines.
 Load cells will be provided vessels to control the quantities of chemicals added and prevent
overfilling.
 Trays will be provided to collect any accidental spillage for recycle or safe disposal.

 Liquid collected by washing equipment at end of a batch is to be collected for re-use in next
batch to the maximum extent possible.
7.2.4 Monomer/ Solvent Tank farm
The tank farm contains large inventory of hazardous chemicals/ solvents. Preliminary details of the
storage tanks for monomers/ solvents planned in the facility are provided in Table 7-5.
Table 7-5: Details of Monomer/ Solvent Storage Tanks

Each Tank
S. No. Description No. of Tanks
Capacity (KL)
1 Styrene 500 5
2 Methyl methacrylate (MMA) 750 4
750 (2)
3 Butyl acrylate 3
500 (1)
4 Butyl methacrylate (BMA) 100 4
5 2-Ethyl hexyl acrylate 250 3
6 Hydroxyethyl methacrylate (HEMA) 75 3
7 Glacial Methacrylic acid 150 3
8 Dipentine 250 1
9 MCEE 10 75 2
10 Mono-ethylene glycol 100 1
11 Di-ethylene glycol 75 2
12 Tri-ethylene glycol 75 1
13 Propylene glycol 150 1
14 Ammonia liquor 100 2

15 HSD 250 1
Note: the capacity and no. of tanks may change during detailed engineering
The properties of monomers/ solvents significant for this risk analysis study are listed in Table
7-6 .
Table 7-6: Properties of Hazardous Materials
Normal
Flash ERPG- ERPG- ERPG-
Boiling LFL UFL IDLH
S.No. Chemical Point 1 2 3
Point
(°C) (°C) (%) (%) (ppm) (ppm) (ppm) (ppm)
1. Styrene (100-42-5) 145 31 1.1 6.1 700 20 130 1100
Methyl Methacrylate
2. 101 11 2.1 12.5 1000 17 120 570
(80-62-6)
Butyl Acrylate (141-32-
3. 145 39 1.5 9.9 NA 8.3 230 480
2)
Butyl Methacrylate
4. 163 54 2.0 8.0 NA NA NA NA
(97-88-1)

Methacrylic Acid (79-

5. 162 77 1.6 8.7 NA 6.7 61 220
41-4)
2-Ethyl Hexyl Acrylate
6. 216 82 0.7 8.2 NA NA NA NA
(103-11-7)
Hydroxy Ethyl
7. Methacrylate (868-77- 226 97 1.5 14.8 NA NA NA NA
9)
8. Dipentene (138-86-3) 157 49 0.7 6.1 NA NA NA NA
Mono-ethylene glycol
9. 197 NA 3.2 NA NA NA NA NA
(107-21-1)
Di-ethylene glycol
(111-46-6)
Tri-ethylene glycol
(112-27-6)
Propylene glycol (57-
55-6)
MCEE10 (Heavy
13. 160 62 0.6 7.0 NA NA NA NA
Aromatics Naphtha)
Meteorological Data used for
Atmospheric stability plays an important role in the dispersion of chemicals. “Stability means, its
ability to suppress existing turbulence or to resist vertical motion”.
Variations in thermal and mechanical turbulence and in wind speed are greatest in the
atmospheric layer in contact with the surface. The air temperature has influenced these
turbulences greatly and air temperature decreases with the height. The rate at which the
temperature of air decreases with height is called Environment Lapse Rate (ELR). It will vary from
time to time and from place to place. The atmosphere is said to be stable, neutral or unstable
according to ELR less than, equal to or greater than Dry Adiabatic Lapse Rate (DALR), which is a
constant value of 0.98 °C per 100 meters.
Pasquill Stability Classes

Pasquill has defined Six (6) stability classes.
 A - Extremely unstable.
 B - Moderately unstable
 C - Slightly unstable.
 D - Neutral
 E - Slightly stable.
 F - Moderately stable.
Three prime factors that defines Stability
 Solar radiation
 Night-time sky over
 Surface wind

When the atmosphere is unstable and wind speeds are moderate or high or gusty, rapid dispersion
of vapors will occur. Under these conditions, air concentrations will be moderate or low and the
material will be dispersed rapidly. When the atmosphere is stable and wind speed is low,
dispersion of material will be limited and air concentration will be high.
The following Table 7-7 of weather parameters representing day and night conditions are
considered for consequence analysis.
Table 7-7: Weather Conditions Considered

Description Unit #1 #2 #3
Wind speed m/s 2 3 5
Ambient temperature °C 20 30 30
Relative humidity % 80 70 70
Atmospheric stability class F D D
7.2.5 Simulation of Release and Development of Contours
Results of consequence analysis for worst case scenarios and maximum credible scenarios using
DNV PHAST software are summarized in the following Tables
Results
The materials involved in storage and transfer system mainly have flammable hazard. The
following materials are considered significant for consequence analysis taking into account boiling
point, flash point.
 Styrene
 Methyl methacrylate
 Butyl acrylate
 Glacial Methacrylic Acid
 HSD
Results of consequence analysis for worst case scenarios and maximum credible scenarios using
DNV PHAST software are summarized in Table 7-8.
Table 7-8: Summary Results of Hazard Analysis

Downwind Distance (m)
Weather
Max.
Parameters
Chemical/ Failure Fire Radiation Intensity Dispersion
(Wind
Equipment Scenario Footprint
speed &
Stability) 4 12.5 37.5 ERPG-
IDLH
kW/m2 kW/m2 kW/m2 2
C1 C2 C3 C4 C5 C6 C7 C8
2 m/s; D 42 17 44 14
Catastrophic Not
Styrene Tank 3 m/s; D 45 18 24 14
failure reached
5 m/s; D 48 20 17 14
2 m/s; D 27 17 6 22 15
Styrene transfer 25 mm leak 3 m/s; D 28 18 6 23 15
5 m/s; D 26 16 6 22 15
Methyl Catastrophic 2 m/s; D 40 18 Not 102 48
Methacrylate Tank failure 3 m/s; D 42 19 reached 86 46

Downwind Distance (m)

Weather
Max.
Parameters
Chemical/ Failure Fire Radiation Intensity Dispersion
(Wind
Equipment Scenario Footprint
speed &
Stability) 4 12.5 37.5 ERPG-
IDLH
kW/m2 kW/m2 kW/m2 2
C1 C2 C3 C4 C5 C6 C7 C8
5 m/s; D 44 20 64 38
Methyl 2 m/s; D 24 15 6 35 16
Methacrylate 25 mm leak 3 m/s; D 25 16 6 36 16
Transfer 5 m/s; D 26 17 6 33 15
2 m/s; D 40 17 - 23
Butyl Acrylate Catastrophic Not
3 m/s; D 42 18 - 21
Tank failure reached
5 m/s; D 45 20 - 20
2 m/s; D 24 15 5 - 19
Butyl Acrylate
25 mm leak 3 m/s; D 25 16 5 - 19
Transfer
5 m/s; D 26 17 6 - 19
2 m/s; D 40 17 - -
Butyl Methacrylate Catastrophic Not
3 m/s; D 42 18 - -
5 m/s; D 45 20 - -
2 m/s; D 24 15 5 - -
Butyl Methacrylate
25 mm leak 3 m/s; D 25 16 5 - -
Transfer
5 m/s; D 26 17 6 - -
2 m/s; D 34 17 - 22
Methacrylic Acid Catastrophic Not
3 m/s; D 36 18 - 21
5 m/s; D 37 19 - 21
Methacrylic Acid 2 m/s; D 20 12 5 - 18
Transfer 25 mm leak 3 m/s; D 20 13 5 - 20
5 m/s; D 20 14 6 - 18
2 m/s; D 36 17 8 - -
Catastrophic
HSD Tank 3 m/s; D 38 19 8 - -
failure
5 m/s; D 40 21 8 - -
2 m/s; D 43 17 - -
Not
HSD Transfer 25 mm leak 3 m/s; D 46 18 - -
reached
5 m/s; D 50 19 - -
Graphical results of consequence analysis plotted on site map showing nearby habitations are
presented in the following pages.

Figure 7-1: Pool Fire Radiation Intensity Risk Contour due to Catastrophic failure in Styrene
Storage Tank at Weather Condition 5 m/s ; D
Figure 7-2: Dispersion footprint (ERPG-2: 130 ppm; IDLH: 700 ppm) Risk contour due to
catastrophic failure in styrene storage tank at weather condition 5 m/s ; D

Figure 7-3: Pool Fire Radiation Intensity Risk Contour due to Catastrophic Failure in Methyl
Methacrylate storage Tank at Weather condition 5 m/s; D
Figure 7-4: Dispersion Footprint (ERPG-2: 120 ppm; IDLH: 1000 ppm) Risk Contour due to
Catastrophic Failure in Methyl Methacrylate storage Tank at Weather condition 5 m/s; D

Figure 7-5: Pool Fire Radiation Intensity Risk Contour due to Catastrophic Failure in Butyl
Acrylate storage Tank at Weather condition 5 m/s; D
Figure 7-6: Dispersion Footprint (ERPG-2: 230 ppm) Risk Contour due to Catastrophic
Failure in Butyl Acrylate storage Tank at Weather condition 5 m/s; D

Figure 7-7: Pool Fire Radiation Intensity Risk Contour due to Catastrophic Failure in Butyl
Methacrylate storage Tank at Weather condition 5 m/s; D
Figure 7-8:Pool Fire Radiation Intensity Risk Contour due to Catastrophic Failure in
Methacrylic Acid storage Tank at Weather condition 5 m/s; D

Figure 7-9: Dispersion Footprint (ERPG-2: 61 ppm) Risk Contour due to Catastrophic
Failure in Methacrylic Acid storage Tank at Weather condition 5 m/s; D
Figure 7-10: Pool Fire Radiation Intensity Risk Contour due to Catastrophic Failure in HSD
storage Tank at Weather condition 5 m/s; D

Remarks on Results of Consequence Analysis
The effect distances for fire radiation and toxic vapour dispersion due to catastrophic failure of
monomer/ solvent storage tank fall within the plant boundary.
As the monomers are liquids with relatively high boiling point, vapour formation even in case of
large liquid release will not be adequate to result in vapour cloud explosion.
7.2.6 Potential for Domino Effect
Potential consequences of any accidents due to domino effect has been reviewed. Domino effect
can be expected in case of vapour cloud explosion or large pool/ jet fire from one equipment
damaging adjacent equipment containing hazardous materials.
Vapour cloud explosion will occur by delayed ignition of a large vapour cloud in flammable range
(above LFL concentration). Consequence analysis for the solvent and monomer tank farm presented
earlier in this report indicates that vapour cloud explosion is not likely in the proposed APL
Visakhapatnam facility because the solvents and monomers have high boiling point (> 100 °C) and
are stored at ambient temperature. Thus domino effect initiated by vapour cloud explosion is not
likely.
In case there is uncontrolled exothermic polymerization of monomer (e.g. Methyl Methacrylate) in

a tank, there will be pressure increase in the tank and the tank roof is expected to fail as the tanks
are designed with fragile roof. This will prevent damage of tank shell and release of liquid into the
dyke. Surface fire may take place inside the tank. Water spray rings around tanks and firefighting
system will ensure that the adjacent tanks are protected.
In the case of damage in one tank due to internal explosion, there may be pool fire in the dyke.
This is already covered in the consequence analysis results presented earlier. In the adjacent tanks,
shell plate will be kept cooled by the liquid contents inside. Additional mitigation will be provided by
water spray rings and firefighting system. This will effectively prevent spread of fire to other tanks.
Based on the above factors, it can be concluded that domino effect accident involving multiple
solvent/ monomer tanks in this facility is not a credible scenario.
7.2.7 Disaster Management Plan (DMP)
Introduction
In recent year’s public awareness of hazards from industry have increased considerably. Local
people and employees have now better legal safeguards against industrial disasters. The
management today has more responsibilities in respect of any kind of disaster in its project. So
specific management plan to encounter a disaster situation is of utmost importance. As disaster
types, sources, effects are different, it needs multidisciplinary and multi-organizational approach to
tackle such situation.
Although a great deal of efforts and money is spent to reduce the scale and probability of
accidents there always remains a finite but small possibility that disaster may occur.
Effective action has been possible due to the existence of pre-planned and practiced procedures or
dealing emergency both.
 Plant and site level using internal resources

 On a large scale utilizing the combined resources of industry and other side services.

Emergency is a general term implying hazardous situation both inside and outside the factory
premises. In order to comply with the provision of the Factories Act and Environment Protection
Act and to ensure the safety of the workers as well as safety of the general public living in the
vicinity of the factory, the risk assessment and emergency planning has been prepared.
The emergency planning will be great help in making the workers safety conscious and make them
confident to handle any type of emergency situation.
Types of Disaster
Disaster is an event /emergency which may cause serious injuries, loss of life, extensive damage
to property or environment or serious disruption inside the plant, or the events that are commonly
having serious implications like major fire hazards, causing serious burns to personnel resulting in
collapse or structures or release or toxic substances in the environment. Disasters can be
1. Plant oriented- due to design errors, operational defects, chemical changes, failure of
equipments human errors etc. (in the plant area).
2. Natural- flood, cyclone, fire, earthquakes, biological disaster.
3. Manmade- war, riot, sabotage.
Degrees of Disaster
Disaster can be classified in 3 types depending on its effects.
1. LOW - can cause injury, illness and equipments damage but not very serious and quickly
manageable.
2. MID - Critical situation, can cause serious injuries to personnel, serious illness property and
equipment damage.
3. HIGH - Catastrophic situation, major danger, can cause deaths, major widespread illness,
injuries, loss of major property and equipments. Immediately uncontrollable.
The above contingencies will be declared by the chief coordinator. The following will be the mode
of action during different degrees of disaster.
1. HIGH DISASTER- Catastrophic condition. All employees to be evacuated. Local administration

to be properly informed and interacted.
2. MID DISASTER- All project activities to be stopped. All employees to be in safe place. To be
ready for High disaster situation. Inform local administration.
3. LOW DISASTER- Activities in the affected area stopped. To be ready for MID disaster
condition.
Stages of Disaster
The duration of disaster's effect can be divided into following stages:
 Warning
 Impact
 Rescue
 Relief
 Rehabilitation

Warning:
The natural calamities which may lead to disasters e.g. flood, tsunami, cyclone can often be
predicted. There are possibilities of disasters during local trouble, riot and war etc. also. All
facilities to encounter the disaster shall be kept ready and employees in full alert.
Impact:
This is the time when the disaster actually strikes and very little can be done to counter the
situation. The impact period may be of few seconds (like explosion or earthquake) or for days (like
flood, fire etc.).
Rescue:
This is the most important stage which starts before the predicted disaster of just after the impact.
All available resources need to be immediately engaged in operation.
Relief:
This is a longer stage of work depending on the degree of disaster. Work during this stage will
need external help for medical, food, clothing and shelter.
Rehabilitation:
This is an important stage in terms of future planning. It includes rebuilding of damaged
properties, restart of project work, compensation etc.
7.2.8 Scope
An important element of mitigation is an emergency planning, 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.
Emergency planning is just one aspect of safety and cannot be considered in isolation. Asian
Paints Limited with a capacity of 5 lakh KL/annum of paints& resins/water based polymers with
fully endorse this fact and hence before starting to prepare the plan, works management will
ensure that the necessary standards, appropriate to safety legislation, are in place.
7.2.9 Objective
Emergency planning for the full range of possible incidents is just one aspect of planning for
safety. It cannot be considered in isolation. The main objectives of the emergency planning are as
follows:
 To assess what dangers could arise to people on and offsite as a result of these foreseeable
emergencies and what the effects could be on the environment.
 To contain and control incidents
 To assess the risk involved and to mitigate the same by preplanned remedial and rescue
measures using, when necessary, the combined resources of the organization concerned and
the public emergency services.
 To safe guard employees, any one nearby, who might be affected and to minimize damage to
property or the environment.
 The training of the individual personnel with duties under the plans will be familiarizing on site
personnel with their roles, their equipment and the details of the plans. Exercises shall be
ensure that the onsite emergency procedures for each process plant, storage facility etc. are

tested regularly and these exercises shall be arranged to test each part of the emergency
plan on each plant, stage by stage, starting with first immediate action.
 The on-site emergency plan shall be based on the specific needs of each particular site for
dealing with those emergencies which it is foreseen may arise.
 For an emergency plan to be successful, it shall be tested, when first devised and thereafter
to be rehearsed at suitable intervals.
7.2.10 Emergency Planning
Disaster Management Plan for an industrial unit is necessarily a combination of various actions
which are to be taken in a very short time but in a present sequence to deal effectively and
efficiently with any disaster, emergency or major accident with an aim to keep the loss of men,
material, plant/machinery etc. to the minimum.
The main functions of the Disaster Management Cell are to prepare a detailed Disaster
Management Plan, which includes:
 Identification of various types of expected disaster depending upon the type of the industrial
unit.
 Identification of various groups, agencies, departments etc. necessary for dealing with a
specific disaster effectively.
 Preparation – by intensive training of relevant teams/groups within the organization to deal
with a specific disaster and keep them in readiness.
 Establishment of an early detection system for the disaster.
 Development of a reliable instant information / communication system.
 Organization and mobilization of all the concerned departments/ organizations / groups and
agencies instantly when needed.
7.2.11 Emergency Scenarios
Various scenarios that are anticipated to cause major emergencies are fire, oil spill, natural
calamities like earthquake, flood, cyclone, tsunami etc. All these scenarios are as following:
 Earthquake
 Flood
 Cyclone
 Tsunami
 Material/ Transport Emergency
 Fire
Earthquake, Flood, Cyclone and Tsunami
Andhra Pradesh is battered by every kind of natural disaster: cyclones, floods, earthquakes
and drought. The coastal region suffers repeated cyclones and floods. The 1977 cyclone and
tidal wave, which resulted in great loss of life, attracted the attention of the central and state
Governments of India and the international donor communities, as did those of 1979, 1990
and 1996. The floods in the Godavari and Krishna Rivers caused havoc in the East and West
Godavari and Krishna districts.
Earthquakes in the recent past have occurred along and off the Andhra Pradesh coast and in
regions in the Godavari river valley. Mild tremors have also hit the capital city of Hyderabad,
for example in September 2000.

Figure 7-11: Earthquake Zone in Andhra Pradesh
Cyclones are caused by atmospheric disturbances around a low-pressure area distinguished by

swift and often destructive air circulation. Cyclones are usually accompanied by violent storms and
bad weather. The air circulates inward in an anticlockwise direction in the Northern hemisphere
and clockwise in the Southern hemisphere. Cyclones are classified as:(i) extra tropical cyclones
(also called temperate cyclones); and (ii) tropical cyclones.
Andhra Pradesh is exposed to cyclones, storm surges, floods and droughts. A moderate to severe
intensity cyclone can be expected to make landfall every two to three years. About 44 percent of
the state is vulnerable to tropical storms and related hazards.
Figure 7-12: Cyclone and Tsunami Zone in Andhra Pradesh

As per Report of ‘Cyclone Hazard Prone Districts of India’ by National Disaster Management
Authority, Government of India, New Delhi, Thirteen coastal states and Union Territories (UTs) in
the country are affected by tropical cyclones. Four states (Tamil Nadu, Andhra Pradesh, Orissa and
West Bengal) and one UT (Puducherry) on the east coast and one state (Gujarat) on the west
coast are more vulnerable to cyclone hazards. Vishakhapatnam district of Andhra Pradesh is
classified in VH (Very High) zone and FLZ (Flood Zone) category in Vulnerable Districts for Cyclone
Wind and Coastal/Inland Flooding area respectively.
In India, the cyclones develop in the pre-monsoon (April to May) and post-monsoon seasons
(October to December), but most of them tend to form in the month of November.
Once the cyclones enter the mainland, they give way to heavy rains which often translate
into floods, as it was the case with the damaging cyclone-induced floods in the Godavari
delta, in August of 1986. Many drought prone areas adjacent to coastal districts in eastern
maritime states are thus vulnerable to flash floods originated by the torrential rains induced
by the cyclonic depression. In addition to cyclones and its related hazards, monsoon
depressions over the north and central areas of the Bay of Bengal move until reaching north
and central India, including portions of Andhra Pradesh, bringing heavy to very heavy rains
and causing floods in the inland rivers between June and September.
Material / Transport Emergency
During transportation of the material, during construction phase emergencies like Fire, Leakage or
Spillage are possible. It may be outside the project premises, at nearby or far locations. Necessary
emergency actions will be initiated from internal or external resources as per the nature of the
emergency.
7.2.12 On Site Emergency Plan
This On Site Emergency Control Plan outlines the response of the management to control
emergencies in the plant. The objective are:
 To outline the responsibilities and functions of the key members of the On-site emergency
response team, to safeguard other employees, the people living in the surrounding area &
environment
 To conduct regular emergency response drills to train employees as per the responsibilities
assigned to them to ensure prompt emergency response
 To provide information to local authorities, local fire brigade, hospitals, factory inspectorate
and all the concerned govt. agencies regarding the plant hazards and equipment, facilities and
procedures provided by the management in case of any emergency.
Identification of the Factory:-
Name & proposed address of the plant: Asian Paints Ltd., Pudi Village, Rambilli
Taluk, Vishakhapatnam district, Andhra Pradesh
E-Mail Address: sameer.salvi@asianpaints.com
Full name & address of the Occupier: ASIAN PAINTS LIMITED, Plot No. 6A,
Shantinagar, Vakola, Santacruz (E), Mumbai - 400055
Telephones nos. (office & residential): 022-62181987
Name & Address of the General Works Manager: Shri Sameer Salvi

Principal Activity and Manufacturing Process
The major activity of the plant will be manufacture of water based paints, solvent-based paints,
resins & Water based Polymers.
Water based & Solvent based Paints Section

Water-based & Solvent-based Paints will be manufactured in batch process. Production Senior
Manager will be in charge of all production activities. There will be a Production Manager to assist
Production Senior Manager in discharging of his responsibilities. Adequately trained staff will be
deployed in all the sections in all the shifts.
Utilities
Utilities shall consist of power, Emergency power, Cooling towers, Reverse Osmosis, Steam Boiler,
Fire hydrant, Chilling plant & Compressor. Senior Manager Plant Engineering will be in charge of
both maintenance and running of Utilities. He will be assisted by Managers. Sufficient number of
trained operators shall be deployed in each shift.
Security & Safety

Security Officer will be in charge of Fire & Security of the plant. Safety Manager will be in charge
of the safety of the plant. Security personnel, Male Nurse & Guards shall be deployed at Main
gate, OHC and other vulnerable areas in each shift. Security Staff and Fire Fighting squads
comprising of employees trained in firefighting techniques shall assist in Fire Fighting and Traffic
control during emergencies. Adequate firefighting & other equipment shall be provided in the plant
to combat fire & other emergencies.
Medical and First Aid

Doctor shall visit the plant everyday at a fixed time and will be available on call round the clock.
Qualified Male Nurses shall be deployed round the clock in the Occupational Health Centre. Tie up
with local hospitals for medical treatment shall be ensured by the Plant. Ambulance along with
trained driver shall be deployed round the clock to attend emergencies. First-Aid boxes shall be
provided in the OHC & other areas as required.
Emergency Control centre

An Emergency Control Centre shall be provided to control and direct all emergency operations.
Following equipment / facilities and Information will be available at the centre:
 Telephone
 Public Address System
 Fire Alarm Addressable & Conventional Control panel
 SCBA & Proximity suit along with additional firefighting equipment
First Person to be contacted in case of Emergency

 General Works Manager,
 Plant Personnel Senior Manager,
 Plant Engineering Senior Manager,
 Security Officer / Supervisor
 Safety Manager,

Identification of Hazards
The types of incidents that can lead to disaster scenarios are listed below:
 Tanker Toppling
 Evolution of Smoke or Fumes due to fire
 Structure Collapse
 Fire & Explosion
 Major Spillage
 Floods
 Tsunami
 Earthquake
Figure 7-13: On-Site Emergency Response Team - General Shift Organization (9.00 am to
5.30 pm)
Site
Main
Controller
Incident Administration Communication Power & Utility

Controller In Charge Senior Manager In Charge
Security / Fire Fire pump

Site Controller Medical Officer
Officer Attendants
Fire Fighting
Security
Squad First Aiders
Guards
/ Other Operators
Figure 7-14: On-Site Emergency Response Team - Other Shift Organization (5.30pm to
9.00am)
7.2.13 General Guidelines
Any of the below mentioned incidents that can lead to disaster scenarios shall qualify for raising an
Alarm and the details are given in Table 7-9.
Table 7-9: List of Possible Disaster Scenarios

S.No. Hazard Particulars
1 Fire & Explosions All types of fires, smoking insulation & auto ignition
2 Major Spillage Liquid RM like Ropaque, etc., Fuel like HSD or FO
3 Tanker Toppling Toppling of tanker leading to spillage

S.No. Hazard Particulars

4 Fuming Evolution of Large quantity of fumes/ smoke due to organic fires.
Major collapse of an equipment / building having potential to cause
5 Structure Collapse
severe loss of life & property
Water logging above 2 feet resulting in machinery / utilities getting
6 Floods
submerged in water
7 Earthquake Natural calamity, having potential to cause severe loss of life & property
7.2.14 Designations during the General Shift hours (9.00 am to 5.30pm)
 Site Main Controller: General Works Manager (Production Senior Manager)

 Incident Controller: Security Officer (Safety Manager)
 Administration In-Charge: Plant administration Senior Manager (Materials Manager)
 Communication Officer: Personnel Senior Manager (Personnel Manager)
 Power and Utility In-charge: Plant Engg. Senior Manager (Maintenance Manager)
 Fire Pump Attendants: Maintenance Electrician & Security Guard
 Medical Officer: Doctor (Male Nurse)
 Site Controller: Section Manager
 Fire Officer: SO (Duty Security Supervisor)
Note: Alternate designation has been indicated in Bracket
7.2.15 Designations during other than General Shift hours (5.30pm to 9.00 am)
Resident Manager shall perform the duties of Site Main Controller / Incident controller. Shift Team
Leader will act as Site Controller. Engineer- Plant engineering shall act as Power and Utility In-
charge. On alarm as described above, Security supervisor will go to the site and act as prescribed.
He will assess the situation and declare emergency if required. If the emergency is declared he
shall arrange to call General Works Manager and other controllers of general shift. Male Nurse
shall perform duties of Medical Officer.
7.2.16 Specific Guidelines
Fire Explosion
1. The person first noticing FIRE should:
 Shout “FIRE FIRE FIRE …."

 Break the glass of Manual Call Point or call on Emergency Telephone Number.
 Inform Sectional Supervisors.
 In case you are a fire squad member, go back to site of incidence and aid in firefighting
along with the sectional firefighting team.
2. On receiving information from the above person, the Section-
 Team Leader will inform the Site Controller and the Engineer - Plant Engineering. The
sectional firefighting team will initially take lead in firefighting using all the locally available
firefighting equipments, till arrival of Fire officer & Incidence Controller and try to prevent
the spread of fire.
 On receiving fire signal on the fire alarm panel (either through breaking of Manual call
point or indication due to smoke/ heat detection system), Security supervisor along with all

the Security Guards except one main gate guard, will reach the site and assess the
condition.
 Main gate Guard shall immediately close the gates and ensure that no personnel / vehicles
except those required for the control of the incident shall be allowed to go out / come in.
 Main Gate Guard shall inform Telephone Operator / Reception in the administration block
who in turn will inform Site Main Controller Incidence Controller and all other Key Persons.
 Incident controller will take charge of the situation along with Site Controller.
 If Incidence is in control, normalcy is restored.
3. If Incidence is not in control; Incident controllers will advise Site Main Controller to
Declare Emergency. Site Main Controller shall arrange to inform Main Gate Guard to
blow Emergency Siren and declare emergency for entire plant. The evacuation Plan
would be decided by Incident controller and would be communicated to the entire
plant through the Public Address System. Site Main controller shall instruct Security
officer to call for Fire Brigade if required.
 The entire firefighting squad of the plant will go to the affected site and take up firefighting
activities under the guidance of Incident controller.
 The entire First aid team shall go to OHC and report to the Medical officer on Duty.
 Use of SCAB & Proximity Suit shall be made wherever necessary.
 Main Gate guard will arrange for an Ambulance to reach the site
 Medical officer/ Male nurse shall keep necessary equipment, medicines, etc. in ready
condition to treat the affected persons. He shall contact local hospitals regarding the
emergency & alert them to receive the affected persons. He shall call for additional
ambulances from local hospitals as per instructions of incident controller.
 On instructions of Incidence Controller, the Power & Utility In -charge will shut off the power
supply to the affected area& depute one shift fitter to pump house.
 On instruction from Incident Controller, Security guard along with Fire pump attendant will
start the hydrant pump.
 Incident controller will ask site controller to arrange for evacuation of the sectional persons
(other than Fire Fighters) if required. Site controller shall stay back to bring the section to
safe shutdown.
 In case of any causality, site controller shall arrange to evacuate them.
 All Sectional Person shall assemble at Local Assembly Points. Headcount will be taken by
Shift Team Leader/ assistant. Site controller shall guide all people assembled at Local
Assembly point to move to Central Assembly Point if required.
 Shift Team Leader in all other sections shall ask staff /workmen in their respective sections
to safely shutdown their areas to bring sections to safe shutdown condition and assemble in
local assembly point. After taking headcount at local assembly point, Shift Team Leader
along with all workmen shall move to central assembly point if required.
 At Central assembly points, Shift Team Leader/ assistants along with their workmen, shall
wait for instructions from Key Persons for carrying out various duties such as:-
o Traffic Controller
o Communication
o Relief, Refreshment / catering facility
o Additional Transport arrangements.
7.2.17 In Case of Major Spillage / Tanker Toppling:
1. The person first noticing the above incidences should:

o Shout “Nature of Incidence…."

o Break the glass of Manual Call Point
o Inform Sectional Supervisors.
o Go back to site of incidence if required.
2. On receiving information from the above person, the Sectional –
o Team Leader will inform the Site Controller and the Engineer - Plant Engineering. On
receiving signal on the fire cum emergency alarm panel, Security supervisor along with all
the Security Guards except one main gate guard will reach the site and assess the condition.
o Main gate Guard shall immediately close the gates and ensure that no personnel / vehicles
except those required for the control of the incident shall be allowed to go out / come in.
o Main Gate Guard shall inform Telephone Operator / Reception in the administration block
who in turn will inform Site Main Controller Incidence Controller and all other Key Persons.
Incident controller will take charge of the situation along with Site Controller. They
shall ensure:
 That the spillage does not catch fire or enter storm water lines and help in arranging for
housekeeping / other contract personnel to clean up the same.
 Caution sign board “CAUTION HAZARDOUS SPILLAGE” is displayed
 Ensure that all energized equipment such as pumps, motors, mixers, grinding equipment etc.
in the vicinity shall be switched off.
 Ensure that the Cotton waste used for cleaning spillages is wet with water before being disposed
off in the scrap yard. The waste Cotton waste used for cleaning spillages should not be stored
on the shop floor in waste bins.
 Make use of spill management kit and vermiculite powder for containment of spills.
 Ensure that the collected spilled material is correctly identified and properly segregated. (All
flammable liquid spills shall be collected in closed containers.)
 In case of spills from a tanker immediately cordon off the area and do not allow any vehicles in
the area.
 The caustic solution will be used for cleaning by housekeeping after dilution so as not to create
a fire hazard because of generation of heat due to concentrated caustic solution.
 In case of Monomer spillage if it is not possible to collect the spilled material then spray 10-
15% sodium hydroxide solution on the spilled material.
 In case the spilled material has entered storm water / effluent line then the Shift Team Leader
shall immediately inform the ETP personnel to take appropriate mitigating action to prevent any
adverse impact on the environment.
3. If Incidence is not in control; Incident controllers will advise Site Main Controller to Declare
Emergency. Site Main Controller shall arrange to inform Main Gate Guard to blow Emergency
Siren and declare emergency for entire plant. The evacuation Plan would be decided by Incident
controller and would be communicated to the entire plant through the Public Address System
Site Main controller shall instruct Security supervisor to call for Fire Brigade if required.
 The entire fire-fighting squad of the plant will go to the affected site and take up firefighting
 Use of SCBA & Proximity suit would be made wherever applicable
 Medical officer / Male nurse shall keep necessary equipment, medicines, etc in ready condition
to treat the affected persons

 He shall contact local hospitals regarding the emergency & alert them to receive the affected
persons
 He shall call for additional ambulances from local hospitals as per instructions of incident
controller.
supply to the affected area & depute one shift fitter to pump house.
 Incident controller will ask site controller to arrange for evacuation of the Sectional persons
(other than Fire Fighters) if required. Site controller shall stay back to bring the section to safe
shutdown.
 All Sectional Person shall assemble at Local Assembly Points. Headcount will be taken by Shift
Team Leader/ assistant. Site controller shall guide all people assembled at Local Assembly point
to move to Central Assembly Point if required.
 In case there are any casualties, Site controller shall arrange to evacuate them.
 Arrange for fire-fighting in the area by laying water and foam hose lines in case a fire occurs in
the area and in case a fire has already occurred in the area, carry out the fire fighting activity.
 Shift Team Leader in all other sections shall ask staff /workmen in their respective sections to
safely shutdown their areas to bring sections to safe shutdown condition and assemble in local
assembly point. After taking headcount at local assembly point, Shift Team Leader along with
all workmen shall move to central assembly point if required.
 At Central assembly points, Shift Team Leaders along with their workmen, shall wait for
instructions from Key Persons for carrying out various duties such as
o Communication
o Additional Transport arrangements
 In case of tanker toppling following activities shall be carried out-
o Extricate the driver and cleaner, if they are trapped

o Hospitalize them if needed
o Close the tanker valves if they are open.
In case of Evolution of large quantities of fumes / smoke due to fires:
A. The person first noticing the above incidence should:
 Shout “Nature of Incidence…."

 Break the glass of Manual Call Point or call on Emergency Telephone extension number
 Go back to site of incidence if required.
B. On receiving information from the above person, the Sectional Supervisor will
inform the Site Controller and the Engineer - Plant Engineering.
 On receiving fire signal on the fire alarm panel, Security supervisor along with all the Security
Guards except one main gate guard, will reach the site and assess the condition.
except those required for the control of the incident are allowed to go out / come in.
 Main Gate Guard shall inform Telephone Operator / Reception in the administration block who
in turn will inform Site Main Controller Incidence Controller and all other Key Persons.

C. If Incidence is not in control, Incident controllers will advise Site Main Controller to
plant through the Public Address System. Site Main controller shall instruct Security
supervisor to call for Fire Brigade if required.
 The entire fire-fighting squad of the plant will go to the affected site and take up fire-fighting
 Instruct Fire Fighting squad to use Self Contained Breathing Apparatus to control fire thereby
effectively mitigating the hazards from Toxic fumes release.
 Medical officer/ Male nurse shall keep necessary equipment, medicines, etc. in ready condition
to treat the affected persons.
 He shall contact local hospitals regarding the emergency & alert them to receive the affected
persons.
 He shall call for additional ambulances from local hospitals as per instructions of incident
controller.
shutdown.
 In case of any causality, site controller shall arrange to evacuate them.
to move to the assembly point decided by the incident controller if required.
 During evacuation-
o Depending on the quantity of smoke and the wind direction, the Incidence controller in
association with the Site Controller will draw an evacuation plan.
o Evacuate all plant personnel to a safe place away from the toxic gases.
o While evacuating keeping the direction of the wind is extremely important.
all workmen shall move to the assembly point decided by the incident controller if required.
 At assembly points as decided by the incident controller, Shift Team Leader/ assistants along
with their workmen, shall wait for instructions from Key Persons for carrying out various duties
such as:
o Communication
7.2.18 In Case of Structure Collapse:
A. The person first noticing the above incidences should:

 Break the glass of Manual Call Point or call on Emergency Telephone extension number.
B. On receiving information from the above person, the Sectional Supervisor will
inform the Site Controller and the Engineer - Plant Engineering.
 On receiving fire signal on the fire alarm panel, Security supervisor along with all the Security
Guards except one main gate guard, will reach the site and assess the condition.
Declare Emergency. Site Main Controller shall inform Main Gate Guard to blow
Emergency Siren and declare emergency for entire plant. The evacuation Plan would
be decided by Incident controller and would be communicated to the entire plant
through the Public Address System Site Main controller shall instruct Security
supervisor to call for Fire Brigade if required.
 The entire firefighting squad of the plant will go to the affected site and take up firefighting
to treat the affected persons.
o He shall contact local hospitals regarding the emergency & alert them to receive the affected
persons
o He shall call for additional ambulances from local hospitals as per instructions of incident
controller.
shutdown.
 In case of any Casualties, Site controller shall arrange to evacuate them.
to move to Central Assembly Point if required.
 Shift Team Leader in all other sections shall ask staff / workmen in their respective sections to
all workmen shall move to central assembly point if required.
 At Central assembly points, Shift Team Leader/ assistants along with their workmen, shall wait
for instructions from Key Persons for carrying out various duties such as:
o Communication


7.2.19 In Case of Any Flood/Tsunami:
A. The person first noticing the above incidence should:

 Break the glass of Manual Call Point or call on Emergency Telephone extension number.
 On receiving information from the above person, the Sectional Supervisor will inform the Site
Controller and the Engineer - Plant Engineering.
B. On receiving fire signal on the fire alarm panel, Security supervisor along with all
the Security Guards except one main gate guard, will reach the site and assess the
condition.
 In case section is getting affected by flood, Site controller / Shift Team Leader immediately stop
all operations and deploy all available persons in removing the machinery / raw materials /
finished goods / packing materials, so that they are not affected by flood.
 Inform Engineer - Plant engineering for power isolation.
 Arrange to remove all the raw materials from the affected site with assistance of all available
personnel in the area.
The Power & Utility In-charge in association with Engineer - Plant Engineering shall
carryout the following activities:
 Go around the plant and check whether water has entered in any of the cable trenches / MCC
panel room in the ground floor inside the factory and if any cables are short-circuited.
 If so they have to immediately arrange to isolate the power supply in that particular line.
 If water has entered in to any of the cable trench(s), arrange to pump out the water from the
cable trench(s).Take assistance from the other plant-engineering operators / contract workmen.
After evacuating water, reset the electrical system to normalcy.
 In case of any abnormal smell / sound in the MCC panel or cable trench the Electrician / DG
operator shall cut off the power supply from all the lines.
The ETP Staff shall carryout the following activities:

 Ensure that no effluent water is allowed to mix with the floodwater.
 Ensure that all the storm water drains are free from choking & other debris particles periodically.
plant through the Public Address System. Site Main Controller shall instruct Security
Supervisor to call the Fire Brigade if required.

 The entire fire fighting squad of the plant will go to the affected site and take up fire fighting
to treat the affected persons.-
o He shall contact local hospitals regarding the emergency & alert them to receive the affected
persons
o He shall call for additional ambulances from local hospitals as per instructions of incident
controller.
 On instructions of Incidence Controller, the Power & Utility In -charge will

 Shut off the power supply to all the affected area & depute one shift fitter to pump house.
 In the event of power shutdown, ensure UPS power is only available for emergency lighting and
emergency systems.
shutdown.
The Security Staff shall carryout the following Activities on Declaration of Emergency:
 A team comprising Security supervisor and two Security guards go around the factory with
necessary Personal Protective Equipment with them to rescue any people in danger.
 They shall also ensure that no material goes out of the factory (e.g. Pallets, Barrels etc.)with
the floodwater to the possible extent.
 The Communication officer shall ensure that enough food materials are available.
 Administration in charge shall ensure that a stand-by car is kept ready, to take the affected
persons to the hospital, in case if the ambulance ceased due to the flood.
to move to Central Assembly Point.
all workmen shall move to central assembly point.
 At Central assembly points, Shift Team Leader/ assistants along with their workmen, shall wait
for instructions from Key Persons for carrying out various duties such as
o Communication
Earthquake (In Case of Earthquake Event)
 In case of an earthquake being felt it is required by all concerned to stop the operations and
evacuate the block and assemble at the assembly point. Site controller and Shift Team Leader
will ensure the evacuation of their respective areas.
 Site controller / Shift Team Leader shall arrange to inform the main gate by telephone/ through
messenger.

 On getting the message of earthquake, main gate guard shall inform the Incident controller/
Site Main controller and declare emergency and announce the nature of emergency through
Public Address system and order for evacuation of entire plant.
 The Power & Utility In-charge along with Engineer - Plant Engineering shall carryout the
following activities:
o If emergency is declared, isolate the power supply from all the lines & shut down the whole
plant.
o In the event of power shutdown, ensure that all non-essential loads are cut-off from UPS
power supply so that emergency UPS power is available for emergency lighting and
emergency systems.
 In case of any eventuality arising due to earthquake like fire, structure collapse, tank toppling
etc… the related emergency plan shall be activated.
7.2.20 Key Persons and Their Responsibilities
Telephone Operator/Reception at the Administration Block
 On hearing emergency siren, ensure that the message is immediately passed to the incident
controller, site main controller & Communication officer & other designated controllers.
 He shall keep the board free for all essential calls.
 He shall also keep the list of all important internal and external phones readily available.
 He shall also keep a record of all incoming and outgoing messages pertaining to the emergency
 He shall not disclose any information pertaining to the emergency to unauthorized personnel
without prior permission of the site main controller.
 He shall subsequently pass all required communication as directed by the different in charges.
Site Main Controller
 Assess the magnitude of the situation and decide if employees need to be evacuated to
assembly point
 Exercise direct operational control over areas other than those effected
 Maintain a continuous review of possible development & assess in consultation with Site
Controller & Incident Controller and other key personnel to shut down the plant or section and
evacuation of persons
 Liaise with senior officials of the company, police, fire brigade, Medical & factories Inspectorate
and provide possible effects on areas outside the factory premises
 Control rehabilitation of affected areas on discontinuation of emergency
 Ensure Evidence is preserved for Enquires to be conducted by Statutory authorities
Incident Controller
 On Emergency rush to the effected site and take over all charge & report to Site Main Controller
 Assess the scale of emergency & decided if major emergency exit or is likely, inform Other
Senior Managers / Section Managers & Communication Officer for possible help required
 Direct all operations with the priorities for safety of personnel, minimize damage to the plant,
property & Environment and minimize loss of material
 Till arrival of SITE MAIN CONTROLLER, assume his duties in
o Directing the shutting down & Evacuation of affected plant

o Co-coordinating with areas likely to be adversely affected by the emergency
o Ensure that all the key personnel and outside help is called in

o Provide advise & information to the Local Fire services as and when arrived
o Ensure that all non-essential personnel are evacuated and areas are searched for causalities
o Report all significant developments to the communication officer
o On failure of power supply set up communication point & establish contact with emergency
control centre
o Ensure evidence is preserved to facilitate any enquiry into the cause
Administration In-Charge
Work as Liaison officer and under the direction of Site Main Controller, handle Police and other
enquiries, receive reports from roll call leaders from assembly points & pass on the information to
Site Main Controller
 Ensure causalities receive adequate attention, arrange additional help if required and to inform
relatives.
 Control Traffic movement into the factory & ensure alternate transport is arranged when need
arises.
 When emergency is prolonged, arrange for the relief of personnel and organize refreshment /
catering facility.
Communication Officer
 All communications will be handled by him. On hearing emergency siren, proceed to Emergency
Control Centre and maintain communication with the Incident Controller.
 Recommend, if necessary, evacuation of personnel from assembly point as per information
received from the Incident Controller.
 Recruit suitable staff to act as runners between the Incident Controller & himself if the telephone
and other communication systems fail.
 Maintain prior agreed inventory in the control centre.
 Maintain a log of the Incident.
 Inform Local authorities, police, hospital, other agencies and Head Office in case of a major
accident hazard.
Site Controller
 Safe shutdown of the affected area or section.

 Segregation & Removal of flammable material from the effected site.
 Provide necessary guidance and help for Fire-fighting squads & Security staff.
 Evacuate other employees to assemble in local assembly point.
 Take Head Count at local assembly point evacuate all central assembly point.
Fire Officer
 He is responsible for fire-fighting in the affected area.

 On hearing the Fire Alarm, rushes to effected area, advise other staff of the incident zone and
cancel the alarm.
 Announce on Telephone or PA system or messengers to the resident executive / communication
officer / Incident controller / Site Main Controller that incident has occurred in such and such
zone.
 Direct the emergency services to the affected area in controlling the emergency.
 Call Fire Brigade on the instructions of Site Main Controller / Incident Controller.

Power & Utility In-Charge
 On hearing the emergency siren, report to the utility control room and close down the services
as requested by the Incident Controller
 Provide necessary back up services for controlling emergency.
 After discontinuation of emergency, Inspection & clearance for restart of the affected area.
 In the event of Power shut down, ensure UPS is only available for emergency lighting and
emergency systems.
Fire Pump Attendants
 Ensure water for hydrant & monitor system are supplied by electrical pump / diesel driven
engine pumps.
 Ensure that pumps starts automatically in sequence with the pressure switches.
 He will remain on standby to start the pumps manually, if necessary.
Medical Officer
 On hearing emergency siren, he will keep necessary equipment, medicines, etc. in ready
condition to treat the affected persons
 Ensure that ambulance is sent to affected areas on advise of Incident Controller for pick up
affected persons
 He will contact local hospitals regarding the emergency & alert them to receive the affected
persons
 He will call for additional ambulances from local hospitals, if needed
General employees who have not been specified a duty in case of emergency should proceed
to/contact the Emergency Assembly Point in their area. Designated persons will carry out the
actions detailed in the Individual Plant Emergency Procedure. The Roll Call leader will hold a Roll
call. Personnel not at their normal work place must go to the emergency assembly point.
Personnel will remain at these points and await instructions from the Site Controller.
Contractor’s Employees
Contractor's employees will be instructed in the Emergency Procedures before commencing work
on this site. They will report to the emergency assembly point on this site. Personnel Manager will
guide them in case a major decision like evacuation from the factory is taken.
Visitors
Infrequent visitors are registered on each visit. They will be given a Visitors pass which includes an
emergency action statement. The responsibility for visitors in emergency situation rests with the
person being visited.
Responsibilities outside general shift hours
Shift Supervisor
 He/she will act as Site controller for the time being. As soon as becomes aware of the
emergency and its location, he will proceed to the scene. He will assess the scale of the
incident and direct operations within the affected areas.
 He/she will contact and inform the Site Controller and Incident Controller immediately. Till
their arrival he will continue to perform their duties.

 He/she will contact the departmental head to act as incident controller and guide Safety
Officer and Security Officers for containing the damage.
 He/she will call the Medical Officer to the plant if necessary. Other staff with designated
responsibilities will act as instructed.
Infrastructure
Fire Fighting Facilities The plant will have adequate firefighting aids including fire hydrants
close to the required locations. There will be Portable Fire Extinguishers of different types and
sizes are installed in specific places. The factory siren will be used for raising the alarm and also
for ALL CLEAR signal
First Aid boxes are provided in specific locations including at the Assembly point for
administering preliminary treatment. A number of employees are trained for first aid use.
Emergency Control Centre is the point from which the Site Controller directs the movements of
Personnel and Equipment during an Emergency.
Contents of Emergency Control Centre:
 External telephone line and a list of relevant telephone numbers. Table 7-10 provides a list
of relevant telephone numbers
 Internal telephone and telephone list of Emergency Assembly Points.
 List of Emergency Control Team, who must be called showing addresses and telephone
numbers.
 Emergency Controller's Red & White Helmet.
 A list of all persons (by title) responsible for groups of employees.
 Logs and Emergency Controller's checklist.
 Emergency lighting.
 Copy of the emergency plan.
 List of persons trained in First Aid & Fire Fighting.
 List of safety cabinets and their contents & locations.
 Battery operated torches.
 Detailed site plan.
 First aid equipment including stretchers (in surgery).
Assembly Point is a place containing an internal telephone and paging system, where people
can wait in a group during emergency to receive instructions from the Emergency Controller.
External Communication will be done by Site Controller. The following persons and offices may
be given updated information as necessary and ask for necessary help.
 District Magistrate
 SDO
 Police
 Fire Brigade
 District Hospital
 Factory Inspector
 Local Media

Emergency Helpline Numbers
Table 7-10: Emergency Helpline Numbers

S. No. Name of Service Contact No.
1. Police Station 100
2. Fire Station 101
3. Ambulance 102,108
040-23451088, 040-23451074 (O)
4. Chief Secretory, SDMA, Andhra Pradesh 040 -23456137 (F)
08499950005 (R)
Control room,
040-23451043,
4. National Disaster Management Authority (NDMA),
040-23451819 (F)
Andhra Pradesh State
040-23237788 (O)
Director General of Police (DGP), Andhra Pradesh
5. 040-23243333 (F)
State
09440627321 (M)
6. Commissioner Disaster Management 040-23456005 (O)
0891-2563257
0891-2509865, 0891-2526999 (O)
7. District Collector, Vishakhapatnam District
9440226777 (M)
0891-2564426 (F)
Superintendent of Police (SP), Vishakhapatnam 9440796000 (M)
8.
District 2551104 (0891)
Source: http://www.ndma.gov.in/en/andhra-pradesh-sdma-office.html
Evacuation, Escape and Rescue (EER) Plan
In a major emergency, it will be necessary to evacuate personnel from effective areas and as a
safety measure to further evacuate non-essential workers from areas likely to be affected should
the emergency escalate. Arrangements could include announcements over the public address
system or through other suitable means.
On evacuation, staff/guests shall be directed to pre-determined assembly points already explained

earlier. If they are required to be evacuated outside the site and at a remote place, their
transportation will be necessary for which vehicles will be required.
During the evacuation, announcements should continue to all areas of the building to reassure
guests/ employees/ students.
Training:
 Training pamphlet will be provides to every occupant

 Mock drills and training on safety aspects will be provided to all construction workers (during
construction phase) and interested residents (during operation Phase)
 Training in use of first aid kit to each personnel
General Measures:
 The fire water tank will be always full by using a baffle wall & there will be fire engine & diesel
engine, in case of power backup

 Safe assembly points

 There will be availability of UPS (Uninterruptible Power Supply), emergency lighting and
emergency announcement system, in case of emergency
 Fire/emergency entry & exit boards will be displayed at suitable locations
 Proper signage
 Emergency phone numbers will be displayed
7.2.21 Do’s and Don’ts
Earthquake Situation
A. Before an earthquake:
 Follow and advocate local safe building codes for earthquake resistant construction.
 Follow and advocate upgrading poorly built structures.
 Make plan and preparation for emergency relief.
 Identify the medical centre, firefighting stations, police posts and organize relief society of
your area.
 Know the electric and water shut off locations in your house.
 Heavy objects, glasses, cutlery shall be kept in lower shelves.
 Flower pots should not be kept on the parapet.
B. During an earthquake:
 Keep calm and reassure others.
 During the event, the safest place is an open space, away from buildings.
 If you are indoors, take cover under a desk, table, bed or doorways and against inside alls
and staircase. Stay away from glass doors, glass panes, windows or outside doors. Do not
rush to go out of the building, to avoid stampede.
 If you are outside, move away from buildings and utility wires.
 Once in the open, stay there till the vibrations stops.
 If you are in a moving vehicle, stop as quickly as possible and stay in the vehicle.
 Free all pets and domestic animals so that they can run outside.
 Do not use candles, matches or other open flames. Put out all fires.
C. After an earthquake:
 Keep stock of drinking water, foodstuff and first-aid equipment in accessible place.
 Do not spread and believe rumors.
 Turn on your transistor or television to get the latest information/bulletins and aftershock
warnings.
 Provide help to others and develop confidence.
 Attend the injured persons and give them aid, whatever is possible and also inform hospital.
 Be prepared for aftershocks as these may strike.
 Close the valve of kitchen gas stove, if it is on. If it is closed, do not open. Do not use open
flames.
 Do not operate electric switches or appliances, if gas leaks are suspected.
 Check water pipes, electric lines and fittings. If damaged, shut off the main valves. Do not
touch live wires of electricity.
 If needed, open doors and cup boards carefully as objects may fall.

Flood Situation
Do’s:-
 Tune to your local radio for warnings and advice.
 Move to higher ground.
 Move vehicles, equipments, chemicals, old persons, children, pregnant women, etc., to higher
and safer places.
 Disconnect all electrical appliances.
 Turn off electricity and gas before you leave the house.
 Tie your valuable items or articles and keep them in a safe and high place or bury
it underground.
 Shift the livestock and cattle to safe places or high land. Keep some feed and fodder for them.
 Insure household articles, livestock and crop.
 Collect your survival kit or basic essentials before leaving your house.
 Think of safety first during a flood.
 Take care when walking through shallow waters.
Don’ts:-
 Do not allow to go in, or near flood waters.
 Do not wander around in a flooded area.
 Do not drive into water of unknown depth and current.
 Do not eat food, which is affected by flood waters.
 Do not try to walk or drive through flood waters.
 Do not walk across bridges as they may collapse.
 Do not contact flood waters to avoid contamination.
 Do not walk through flowing water - currents can be deceptive, and shallow, fast moving
water can knock you off your feet.
 Do not swim through fast flowing water or you may get swept away or struck by an object in
the water.
Cyclone Situation
Do’s:-
When the Cyclone starts
 Listen to the radio (All India Radio stations give weather warnings).
 Keep monitoring the warnings. This will help you prepare for a cyclone emergency.
 Pass the information to others.
 Ignore rumors and do not spread them; this will help to avoid panic situations.
 Believe in the official information
 When a cyclone alert is on for your area continue normal working but stay alert to the radio
warnings.
 Stay alert for the next 24 hours as a cyclone alert means that the danger is within 24 hours.
When Evacuation is instructed
 Pack essentials last a few days. These should include medicines, special food.
 Head for the proper shelter or evacuation points indicated for your area.
 At the shelter follow instructions of the person in charge.

 Remain in the shelter until you are informed to leave
Post-cyclone measures
 You should remain in the shelter until informed that you can return to your home.
 You must get inoculated against diseases immediately.
 If you have to drive, do drive carefully.
 Clear debris from your premises immediately.
 Report the correct losses to appropriate authorities.
Don’ts:-
 Do not spread rumors
 Do not worry about your property
 Strictly avoid any loose and dangling wires from lamp posts.
Tsunami Situation
Do’s:-
Before Tsunami
 Plan evacuation routes from your workplace, or any other place you could be where tsunamis
present a risk.
 Practice your evacuation routes.
During Tsunami
 Use a Weather Radio or stay tuned to a local radio or television station to keep informed of
local watches and warnings.
 Be aware of tsunami facts. This knowledge could save your life! Share this knowledge
 Move immediately to higher ground,
 Stay away from rivers and streams that lead to the ocean as you would stay away from the
beach and ocean if there is a tsunami. A regional tsunami from a local earthquake could strike
some areas before a tsunami warning could be announced.
 Staying away from all low-lying areas is the safest advice when there is a tsunami warning.
After a Tsunami
 You should continue using a Weather Radio or staying tuned to a Coast Guard emergency
frequency station or a local radio or television station for updated emergency information.
 The Tsunami may have damaged roads, bridges, or other places that may be unsafe.
 Check yourself for injuries and get first aid if necessary before helping injured or trapped
persons.
 If someone needs to be rescued, call professionals with the right equipment to help.
 Use the telephone only for emergency calls. Telephone lines are frequently overwhelmed in
disaster situations. They need to be clear for emergency calls to get through.
 Stay out of a building if water remains around it. Tsunami water, like floodwater, can
undermine foundations, causing buildings to sink, floors to crack, or walls to collapse
 Look for fire hazards. Under the earthquake action there may be broken or leaking gas lines,
and under the tsunami flooded electrical circuits, or submerged furnaces or electrical
appliances. Flammable or explosive materials may have come from upstream. Fire is the most
frequent hazard following floods.

 Check for gas leaks. If you smell gas or hear a blowing or hissing noise, open a window and
get everyone outside quickly. Turn off the gas using the outside main valve if you can,
 Look for electrical system damage. If you see sparks or broken or frayed wires, or if you smell
burning insulation, turn off the electricity at the main fuse box or circuit breaker. If you have
to step in water to get to the fuse box or circuit breaker, call an electrician first for advice.
Electrical equipment shall be checked and dried before being returned to service.
Don’ts:-
 Avoid downed power lines and stay away from damaged buildings and bridges from which
Heavy objects might fall during an aftershock.
 Do not use candles.
Fire Safety
Do’s:-
 Train staff in fire safety.
 Ensure presence of sufficient exit routes.
 Make personnel aware about the do’s & don’ts.
 Put up an emergency plan and fire notices in place.
 Keep electrical inspection and testing up to date and carry out repairs.
 Secure safe location of kitchen and its safety.
 Check the adequacy of firefighting apparatus and its maintenance.
 Ensure fire escape routes and fire exit doors/ passageways are unobstructed and doors open
correctly.
 Keep first aid kits ready.
 Conduct fire drills.
 Consult local fire brigade and implement its recommendations.
 Exit from the school to an open area.
 Execute evacuation plan and practice fire drills.
 Call the Fire Brigade.
 If the room is filled with smoke, ask persons to stay low to the ground during exit.
 Identify the fire hazards and areas where fire might start in the school/collage.
 Feel any closed door to see if they are hot before they are opened.
 If the door is hot, use the nearest window or another exit.
 Comfort distressed person.
 Alert the nearest hospital/authority.
 Ensure that all students have reached their homes safely.
 Review the fire risk management plan and evacuation plan.
Don’ts:-
 Do not issue license without checking up the safety of the building.
 Do not allow students and teachers to panic.
 Do not let anyone hide. Ensure that nobody is trapped in toilets/indoors.
 Do not try to contain the fire, if not possible.
 Do not re- enter or permit anyone to enter the building, unless the fire officials have given
permission to enter.

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Annexure 3: Document of Risk

7.2 Risk Assessment Study / Hazard Identification and Consequence Analysis

7.2.1 About PHAST Software

PHAST Professional’s sophisticated modeling calculates distances effect produced by hazardous

The salient features of this package:

 Defines the LEL and UEL zone

 Cloud concentration at user defined time as well as location

KADAM ENVIRONMENTAL CONSULTANTS | JULY 2016 230

7.2.2 Hazard Identification

 Raw material powder handling and storage

Table 7-2: Important Hazardous Events

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Type of Event Explanation

7.2.3 Hazard and Damage Assessment

Consequences of Fire/Heat Wave

Table 7-3: Damage due to Radiation Intensity

Table 7-4: Overpressure Damage

0.027 Limited minor structural damage

KADAM ENVIRONMENTAL CONSULTANTS | JULY 2016 232

Overpressure (bar) Damage

Source: CCPS Consequence Analysis of Chemical Release

Raw Material Powder Handling and Storage

 No grinding operation will be carried out in the facility.

Water based paint plant

KADAM ENVIRONMENTAL CONSULTANTS | JULY 2016 233

7.2.4 Monomer/ Solvent Tank farm

Table 7-5: Details of Monomer/ Solvent Storage Tanks

10 Mono-ethylene glycol 100 1

13 Propylene glycol 150 1

14 Ammonia liquor 100 2

KADAM ENVIRONMENTAL CONSULTANTS | JULY 2016 234

Methacrylic Acid (79-

8. Dipentene (138-86-3) 157 49 0.7 6.1 NA NA NA NA

Meteorological Data used for

Pasquill Stability Classes

Three prime factors that defines Stability

KADAM ENVIRONMENTAL CONSULTANTS | JULY 2016 235

Table 7-7: Weather Conditions Considered

7.2.5 Simulation of Release and Development of Contours

Table 7-8: Summary Results of Hazard Analysis

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Downwind Distance (m)

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Remarks on Results of Consequence Analysis

7.2.6 Potential for Domino Effect

In case there is uncontrolled exothermic polymerization of monomer (e.g. Methyl Methacrylate) in

7.2.7 Disaster Management Plan (DMP)

 Plant and site level using internal resources

KADAM ENVIRONMENTAL CONSULTANTS | JULY 2016 243

Disaster can be classified in 3 types depending on its effects.

1. HIGH DISASTER- Catastrophic condition. All employees to be evacuated. Local administration

The duration of disaster's effect can be divided into following stages:

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An important element of mitigation is an emergency planning, i.e. identifying accident possibility,

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7.2.10 Emergency Planning

7.2.11 Emergency Scenarios

Earthquake, Flood, Cyclone and Tsunami