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CHAPTER- 8 RISK AND SAFETY MANAGEMENT

8.1 INTRODUCTION

Increasing use of hazardous chemicals as raw materials, intermediates and finished

products has attracted attention of the Government and the public at large in view of
the chemical disasters. The serious nature of the accidents, which cause damage to
the plant, personnel and public, has compelled industries to pay maximum attention to
the safety issues and also to effectively manage the hazardous material and
operations. It is mandatory for the industries handling hazardous chemical to maintain
specified safety standards and generate an on-site emergency plan and keep it linked
with off site emergency plan.

The safety management includes the implementation of preventive methods or

accident prevention methods to avoid incident or accident and handling of emergency
in case of accident.

ALPL is very much aware for the risk associated with the various hazardous
chemicals stored and handled in the existing plants and therefore, it has provided all
the adequate safety measures in the existing plant. In addition to this, safety audit has
been carried out by authorized agency every year and suggestion/recommendations
after the audit are implemented regularly.

8.2 DETAILS OF HAZARDOUS CHEMICALS

8.2.1 Hazardous Chemicals

The various hazardous chemicals per the MSIHC rules 1989 & 2000 are being stored
and handled by unit in terms of products, raw materials including solvents and fuels
and after the proposed expansion requirements of these chemicals will be increased
with the augmentation of new chemicals. Details of such chemicals are given in the
following Table-8.1. Details of all the product and raw matrials with respect to general
properties, mode of packing & storage, maximum storage capacity at a time, means of
transportation, market availability etc. are provided in the Chapter-2 under Section-
2.8.

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Table-8.1: Details of Hazardous Chemicals per the MSIHC rules 1989 & 2000

Explosive NFPA
Sp. Vapour Melting Flash Solubilit
Sr. Name of Boiling limit TLV Code
State Colour Odour Gravity Density Point Point0 y in Hazchem Hazardous
No. Chemicals 0 0 0 Point0C LEL UEL ppm
C C C C water F H R
% %
Acetone Fragrant Corrosive,
1. Liquid Colourless 0.791 2 -94.7 56.48 -20 2.6 12.8 750 Miscible 2 YE 3 1 0
Mint Flammable
Clear or water 2SE/ Corrosive,
2. Formaldehyde Liquid Pungent - - - 19.4 0C 85 7 7.3 - Soluble 4 2 0
white 2T Flammable
Characteri
Clear
stic Infinitely
3. Formic Acid Liquid Colourless 1.22 1.6 8 101 50 18 57 5 2R 2 2 1 -
Pungent Soluble
Liquid
Odor.
Hydrochloric Sharp Soluble
4. Liquid Colourless 1.19 - -114.3 -84.8 - - - 2 2R - - - Corrosive
Acid irritating
20C
Methanol Colourless, Alcoholic Corrosive,
5. Liquid 0.79 1.1 -97.8 64.5 16.1 6 36.5 200 (Liu) q 2 PE 3 1 0
waterly Odour Flammable

Odourless Sparingly
6. Nitrogen Liquid Colourless 0.808 - -210 -195.6 - - - - 2RE 0 3 0 -
Soluble
Sodium White Flakes Odourless
7. Liquid 2.12 - 318.4 1390 - - - - Soluble 2R 0 3 1 Corrosive,
Hydroxide /Pellets
Toluene Pleasant -95 to Slightly
8. Liquid Colourless 0.817 3.14 110.4 12.7 1.2 7 100 3* 3 2 0 Flammable
94.5 soluble
Xylene Sweet Corrosive,
9. Liquid Colourless 0.864 - - 134-140 37.7 - - 100 insoluble 3* 3 2 0
Odour Flammable

Note: F: Flammable, E: Explosive, C: Corrosive, T: Toxic, P: Poisonous, R: Reactive

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8.2.2 Storage Elements

Storage area provided for existing chemicals and provision for proposed chemicals
are given in Chpater-2 in Table-2.5 and Table-2.6. However, storage details of some
specific chemicals are discussed here below.

Methanol: Unit is using Methanol which is classified as flammable and poisonous

chemical. Unit has obtained License for use of methanol from Petroleum & Explosive
Safety Organisation (PESO) under the Petroleum Act, license for Petroleum Class-A
vide license no. P/WC/GJ/16/267(P183756) which is valid upto 31-Dec-15 and from
Superintendent of Prohibition and Excise, Baroda vide license no. 154/13-15 which is
valid up to 31-Mar-15 for usage of 50 KL Methanol. Methanol is stored in the 220 Ltrs
drums in the separate area.

Other Hazardous Chemicals: Flammable chemicals such as Toluene, Acetone,

Isopropyl Alcohol etc. and gas cylinders of Mono Methyl Amine, Anhydrous HCL, N2,
Oxygen etc are stored in open area outside the plant with all the safety measures.
Hazardous chemicals bags/drums are stored and handle in Dispensing room for taking
out sample from the container for quality check up purpose or for the partial use.
This activity for Hazardous material handling is carried out by using all PPE with
proper ventilation & under supervision.

8.3 SAFETY MEASURES

8.3.1 Safety Mesures for Methanol

For Storage/Handling:

Stored separately from strong oxidant & kept it in well ventilated room.
Dyke wall is provided to all above ground storage tank.
Fire hydrant system is installed.
Safety shower and eye washer are installed near storage area.
Flame proof light fitting are provided at storage area.
Sprinkler system are installed near storage area
Earthing/bonding is provided for static charges.
Flame arrestor is provided on storage tank vent.
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Level gauge and level measurement instruments are provided storage tank.
Safety permit system is followed for loading and unloading
Isolate storage is provided with wire fencing under lock and key
Caution note, hazardous identification board is provided.
Only authorized person is permitted in storage tank area and register is
maintained.
DCP type fire extinguishers are provided
No smoking Board is displayed
Wind Indicator and siren are provided

For Transportation & Unloading:

It is received by road tanker and stored in storage tank in separated storage area.
Safe procedure for loading and unloading is prepared
Flexible steel hose is used for unloading from the tanker.
Flame proof electric motor is used during loading/unloading.
NRV is provided on pump discharge line.
Fixed pipeline with pumps is provided for transfer to vessel.
TERM CARD is provided to all transporters and are trained for transportation
Emergency of hazardous chemicals.
Personal Protective Equipment (safety goggles, hand gloves, apron, masks, gum
boots etc.) are provided.

8.3.2 General Safety Measures For Storage

For the safe storage unit has provided the following safety measures and after
proposed expansion all the necessary safety measures will be provided:

Display Boards are provided on all storage areas and tanks which includes the
name of the product, stored Material of construction, Calibration of tanks and date
of Painting.
In order to avoid the accident due to spillage or overflow, the level indicators are
placed which helps to know the exact liquid level inside the tank.
All the storage tanks are provided with Dyke wall and transferring pumps which
helps to reduce the risk of tank leakages.

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Proper earthing is provided to all storage tank to prevent the firing due to static
charges.
All storage tank are provided with vent line which helps to release the vapours
formed inside vessels and hence reduce the inside pressure of the vessels.
Breather Valves and Flame arrestors are provided on flammable liquid storage
tanks to prevent the firing.
Hazardous display board and national fire prevention association code are
displayed on all storage tanks.
Mountings like Temperature indicator and pressure gauge are provided to all
storage tanks for measuring the physical conditions of materials stored in it.
On-site detectors for fire based on heat &/or smoke detection with alarm system
are provided as per requirement.
Fire hydrants are provided as per requirement.

8.3.3 Safety Mearures For The Transportation

Chemicals are transported by tankers and by closed vehicles.
PUC certified vehicles are used
Standard procedure is followed for safe unloading.
Static earthing provision has been made for tanker unloading.
Fixed pipelines with flameproof pumps are provided for solvent transfer up to
reactors.
NRV provision is made on all pump discharge line.
Drum handling trolleys is used for transportation of drums up to plant.

8.3.4 Safety Measures related to Manufacturing Process

Process parameters control is provided vide Standard Operating Procedures.
Materials are transferred by pumping through pipeline or by vacuum from drums.
Hazardous chemicals are transferred by pipelines and in control manners.
Trained person is engaged for handling of hazardous materials.
Proper safety precautions are taken during handling of hazardous materials.
All solvents and flammable material storage tanks are provided away from the
process plant and required quantity of material is charged in reactor by pump or by
gravity from day tank.

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Further all the vessels are examined periodically by a recognized competent

person.
All the vessels and equipments are earthed appropriately and well protected
against Static Electricity.
Temperature indicators are provided near all reactor and distillation systems.
Caution note, safety posters, stickers, periodic training & updation in safety and
emergency preparedness plan are displayed and conducted.
Flame proof light fittings are installed in the plant.
All the Plant Personnel are provided with Personal Protection Equipments to
protect against any adverse health effect during operations, leakage, spillages or
splash. PPE like Helmets, Safety Shoes, Safety Glasses are provided to the
employees.
Material Safety Data Sheets of Raw Materials & Products are kept readily available
at the shop floor.

8.3.5 Safety Measures For Preventive Maintenance

The safety measures in form of the general Do's & Don'ts for safety in process & other
plant area are as below:
Do not work on equipments without permission from plant head and maintenance
head.
Check VOC content for flammable and make sure that no flammable vapour
contents.
Keep proper and adequate fire extinguisher near work area.
Use proper PPE.
Do not allow any employment without pre-medical check-up or without checking
fitness.
Check all motors are disconnected and fuse pulled out before maintenance.
Work in any equipment must be conducted in presence of supervisor.
Make sure all process lines are disconnected.
Additional safety measures in form of the checklist covering Do's & Don'ts of
preventive maintenance, manufacturing utility staff for safety related measures are
be updated timely and are made available to all concern department & personnel.

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8.3.6 Safety measures to prevent spillage / leakage of toxic chemicals

The preventive maintenance is planned and carried out as per plan to avoid the failure
of valve, pipe lines and other component of transferring line. The spillage will be
confined to the dyke area underneath the vessel. The resultant splash of such
chemicals will result in exposure of toxic chemicals to employees. Decontamination
facilities (Safety shower and eye wash fountains) are provided in the plant area,
which can be used to decontaminate the affected employees.

Suitable decontamination procedure is used to decontaminate the spilled or leaked

material. The SOP for decontamination is reared with all related department. The
followings are some measured taken for handling the toxic chemicals safely.

Safety equipments likeelectric siren, safety belts, safey shower etc are provided at
various places in plant (Refer Table-8.2)and Suitable personal protective
equipment like splash goggles, gloves and protective clothes are provided while
handling the toxic chemicals and details of the same are given in Table-8.3.
The installation of all the equipment is as per guidelines of provision of Gujarat
Factories Rule 1963.
All the toxic chemicals are being stored under adequate safe condition.
The storage of corrosive and toxic chemicals is segregated from each other.
The piping is examined thoroughly every year for finding out any defects; and a
defect is removed forthwith. The record of such examination is maintained.
Smoking is prohibited inside the factory. Train employees are employed for
handling of toxic and corrosive chemicals.
All pipe joints are provided with heavy duty champion gaskets to prevent any
leakage.
Self breathing apparatus are provided and workers are trained about their use
also.
Dyke wall is provided to tank farm area where hazardous chemicals are stored.
Spare barrels of sufficient quantity are kept ready for any emergency spillage or
leakage.
Dyke wall is provided to tank farm area where hazardous chemicals are stored.
Drum trolley is used for the movement of drums of hazardous chemicals.

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Most of the liquid chemicals are transferred by mechanical seal pump through
closed pipeline.
Table-8.2: Details of Safety Equipments
SR.
Name Quantity
NO.
1 Wind Sock indicator 02
2 Electric Siren 01
3 Safety Belts 05
4 Safety Shower 07
5 SCBA Set 45 minutes 03
6 First Aid Box 10

Table-8.3: Details of Personal Protective Equipments

Reserved
SR. Issued Proposed
Name Qty.
NO. Quantity Quantity
In Nos.
1 Safety Helmet 455 50 600
2 Safety Goggles 365 150 200
3 Hand Gloves (PVC) 165 25 50
4 Hand Gloves (Rubber) 1020 400 200
5 Hand Gloves (Disposable) 4500 1500 500
6 Hand Gloves (Cotton) 700 100 300
7 Dust Mask (Cotton) 280 150 400
8 Dust Mask (Acid/Alkali 50 25 60
Cartiledge)
9 Safety shoes 321 10 600
10 Shoes cap(Disposable) 5000 1500 500
11 Head cap (Disposable) 5000 1500 500
12 Aprons (Cotton) 32 10 20
13 Aprons (PVC) 15 6 50

8.4 FIRE FIGHTING SYSTEM AND EMERGENCY MANAGEMENT

8.4.1 Fire fighting system

Adequate system is provided by the unit for fire fighting as described below;
Sufficient numbers of Fire extinguishers are installed in all plants and storage area.
Fire hydrant system is installed in the plant.
Separate Water storage tank is provided for fire water as well as process water
requirement.

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D.G. Sets is provided for emergency power.

Mock drill & training is conducted at scheduled intervals.
Fire fighting team members are available at any time in the premises.
Separate fire water reservoir of 700 KL Capacity is provided with diesel driven pump
of 171 M3/hr & Jockey pump of 10.8 M3/hr. There are 42 hose reels of 15 m lenth. In
addition to this, if require fire system of Padra is at 25 Km distance. Details of fire
control equipments are given in Table-8.4 and Table-8.5

Table-8.4: Details of Fire Extinguishers

Sr. Location Types Capacity (kg)

No.
1 Plant Electrical Panel F/F Entrance CO2 4.5 Kg
2 Plant Electrical Panel G/F Entrance CO2 4.5 Kg
3 Engg. Electrical Panel Entrance CO2 4.5 Kg
4 Utility Entrance DCP 5 Kg
5 Utility Near Reactor DCP 5 Kg
6 Utility Near Reactor CO2 4.5 Kg
7 RM store Receiving Area Entrance CO2 4.5 Kg
8 RM store Nr. Hoist CO2 4.5 Kg
9 RM store Nr. Sampling Room M. Foam 50 Ltr
10 Finished Good AC Storage Entrance DCP 5 Kg
11 Drum Yard Entrance CO2 4.5 Kg
12 MeOH Godown Entrance DCP 5 Kg
13 MeOH Godown Entrance DCP 10 Kg
14 P-1 PP Area Nr. FBD-101 CO2 4.5 Kg
15 P-1 PP Area Nr. FBD-102 DCP 5 Kg
16 P-1 F/F Nr. SSR-101 DCP 2 Kg
17 P-1 G/F Nr. RCF-103 CO2 4.5 Kg
18 P-1 G/F Nr. Hoist CO2 4.5 Kg
19 P-1 G/F Nr. Entrance CO2 4.5 Kg
20 P-1 G/F Nr. Entrance DCP 5 Kg
21 P-1 G/F Nr. Entrance M. Foam 50 Ltr
22 P-1 F/F Nr. Staircase M. Foam 50 Ltr
23 P-4 F/F Nr. GLR-405 CO2 4.5 Kg
24 P-4 F/F Scrubber Area Entrance CO2 4.5 Kg
25 Scrubber Area Entrance DCP 5 Kg
26 P-3 T/F Nr. GLR-305 DCP 5 Kg
27 P-3 F/F Nr. GLR-302 CO2 4.5 Kg
28 P-3 G/F PP Area Entrance CO2 4.5 Kg
29 P-3 G/F PP Area Nr. FCP-301 CO2 4.5 Kg
30 P-3 G/F Dryer Room Entrance DCP 5 Kg
31 AHU-1 Entrance Terrace DCP 5 Kg
32 P-3 Entrance Terrace CO2 4.5 Kg

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33 AHU-1 Entrance Terrace DCP 5 Kg

34 Instru. Room-1 Nr. HPLC-57 DCP 2 Kg
35 Instru. Room-1 Nr. Entrance DCP 2 Kg
36 R & D Lab. Nr. Entrance DCP 2 Kg
37 Security Office Entrance DCP 5 Kg
38 Instru. Room-1 Nr. HPLC-57 P.A. 250 Gm
39 Instru. Room-1 Nr. GC-09 P.A. 250 Gm
40 Wet Lab. Nr. Potensiometer P.A. 250 Gm
41 ADL Lab. Nr. Entrance P.A. 250 Gm
42 Gen. Shift Bus Nr. First Seat DCP 1 Kg
43 P-1 GLR-104 DCP 5 Kg
44 P-1 GLR-105 DCP 5 Kg
45 P-1 F/F Nr. Staircase DCP 5 Kg
46 P-1 F/F Nr. SSR-103 CO2 4.5 Kg
47 P-1 F/F Nr. Hoist CO2 4.5 Kg
48 ETP Entrance CO2 4.5 Kg
49 P-2 Entrance DCP 5 Kg
50 P-2 Entrance DCP 5 Kg
51 P-4 G/F Entrance CO2 4.5 Kg
52 P-4 F/F Nr. GLR-405 DCP 5 Kg

Table-8.5: Details of Fire Hydrants

Type Qty. Pressure
Fixed 21 7.0 Kg.
Portable 01 7.0 Kg.

8.4.2 Emergency Management

Emergency Planning:
Emergency siren and wind sock is installed.
On Site emergency Plan is prepared.
Tele Communication system and mobile phone is used in case of emergency
situations for communication.
First Aid Boxes and Occupational health centre are made at site.
Safety Practices in the Work Area:
Unit provides information to all employees about the potential hazards of
contact with chemicals and trains them in appropriate first-aid procedures.
Chemical handling areas are clearly marked and restricted to qualified, trained
personnel only.

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Emergency Procedures
In case of emergencies first aid and emergency response procedures are
adopted
Transportation Emergencies
In emergency situations resulting from vehicle accidents:
Notify the local police, fire departments, emergency responders and the carrier.
Isolate the area.
Any person not dressed in proper protective clothing and not using a NIOSH
approved self-contained breathing apparatus should be kept a safe distance
away.
Call to the supplier.
Seek immediate medical assistance for those injured and follow recommended
first aid procedures.
Leaking Containers
When handling a leaking bottle personal protective clothing, goggles and
NIOSH approved self contained breathing equipment must be worn.
Clear contaminated area of non-essential personnel and send them to
assembly point.
There should be provision of proper ventilation. Scrub the floors and equipment
with soap and water.

First Aid Procedure

For skin contact, immediately flush skin with plenty of water for at least 15
minutes while removing contaminated clothing and shoes.
To avoid the risk of static discharges and gas ignition, soak contaminated
clothing thoroughly with water before removing it. Wash clothing before reuse.
Clean shoes thoroughly before reuse. Get medical attention immediately.
In all cases of injury, obtain immediate medical attention.
Provide emergency personnel with information about all materials used by the
person

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8.5 ONSITE EMEREGENCY PLAN AND DISASTER MANAGEMENT PLAN

Unit has prepared on-site and off-site emergency plan and same has been regularly
updated. After the proposed expansion also all the required safety measures will be
implemented as well as on-site and off-site emergency plan will be revised and
updated with respect to the proposed expansion. On-site and off-site emergency plan
for the existing unit is enclosed as separate report with the EIA reprot.

8.6 OCCUPATIONAL HEALTH & SAFETY PROGRAM

Health hazards associated with the occupation are called occupational hazards. Due
to handling of toxic and hazardous chemicals there are possibilities of developing
occupational diseases.The Management has prepared environment, health & safety
policy as well as safety manual, safely booklet etc. for enhance safety culture in the
company. The medical chec-up program is implemented as pre-employment, post-
employment and regular check-up programs. Medical check-up of all the employees
are carried out periodically by Dr. Kailash Agrawal, M.B.B.S, DIH (Visiting FMO) and
health records are maintained as per the Factory Act in Form No. 33. Same practice
will continue after the proposed expansion.
Some of the safety measure carried out by ALPL to ensure prevention of occupational
hazards is delineated below;
Suitable personal protective equipment like safety gloves, helmets, safety belts,
first aid boxes is provided to personnel in the plant & detail of the same is given in
Table-8.3.
Use of protective equipments is regularly checked and is kept easily accessible
and easily workable during emergency.
Monitoring of occupational hazards like noise, ventilation is carried out at frequent
intervals.
The workers exposed to higher noise level are provided with ear muffs/ ear plugs.
Drinking water supply for the employees is provided as per standard of the drinking
water as per WHO guidelines.
Proper sanitary facilities are made available so that employees do not suffer from
any health ailments.
Training includes information on accident prevention, proper control and
maintenance of equipment, first aid training and safe material handling practices.

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MSDS of the chemical used are made available at the place of use.
Storage and process areas are posted with No Smoking signs. Smoking is
prohibited throughout the factory. All management staff, Executives on their rounds
to factory ensures the compliance.
Adequate ventilation is provided in process area so that airborne concentration
does not exceed threshold limit value.
Few common antidotes are available all time at site and unit will keep more
antidotes as per requirement after proposed expansion.
In addition to regular control measures to prevent the health hazards to the workers,
the following check-up are carried out regularly to avoid occupational hazard.
Pre-employment medical check-up at the time of employment.
The unit has appointed the medical officer for the regular medical examination and
treatment of the employee.

Treatment for Workmen Affected By Accidental Methanol/Phenol

Hazards with Acute Exposure
Contact with skin may cause severe burns or systemic poisoning.
Systemic effects may occur from any route of exposure, especially after Skin
absorption.
Hazards with Chronic Exposure
Repeated or prolonged skin exposure to phenol or vapors from heated phenol may
cause Headache, nausea, dizziness, diarrhea, vomiting, shock, convulsions and
death
Methanol affects the central nervous system, liver, and kidneys.
Special Safety Precautions
Prevent contact with skin by wearing neoprene gloves, lab coat and resistant
apron.
Wear safety glasses or a face shield if splashing may occur.
Store in a cool, dry, well-ventilated area, away from heated surfaces or ignition
sources.
Skin contact requires immediate washing of the affected area with soap and water.
Remove contaminated clothing and launder before wearing again.
Procedure for treating workmen after skin contact

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Skin contact requires immediate flushing of the contaminated area with soap and
water at a sink or emergency shower for a good fifteen minutes.
Remove contaminated clothing.
In case of eye contact, promptly flush the eyes with copious amounts of water for
15 minutes (lifting upper and lower lids occasionally) and obtain medical attention.
If methanol is ingested, obtain medical attention immediately.
If large amounts of methanol are inhaled, move the person to fresh air and seek
medical attention at once.
It is recommended to provide the safety shower and eyewash station in plant.
Antidotes for Methanol
Fomepizole
Thanol
Antidotes for Phenol
Poly Vinyl pyrrolidone (PVP).
Polyethylene glycol 300 or 400
Thainol

8.7 RECOMMENDATIONS
In addition to the safety measures taken by the unit, following steps are recommended.
Plant should meet provisions of the Manufacture, storage & Import of Hazardous
Chemicals Rules, 1989 & the factories Act, 1948.
Emergency handling facilities to be maintained in tip top condition at all time.
Safe operating procedure to be prepared for hazardous process and material
handling process
Safety devices and control instruments to be calibrated once in a year.
Fire hydrant system needs to be installed as per NFPA Norms in each plant and
buildings.
Proper colour work to plant pipeline and tank, equipments to be done once in a six
month to protect from corrosion.
Preventive maintenance schedule and record should be maintained for all
equipments.
Permit to work system is and should be maintained for hazardous work in the plant.

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Periodic on Site Emergency Mock Drills and occasional Off Site Emergency Mock
drills to be conducted, so those staffs are trained and are in a state of
preparedness to tackle any emergency.
Safety manual shall be prepared and the same will be distributed to all employees
and nearby public.
Emergency siren to be provided in the plant to declare emergency.
Manual call points for fire location identification to be installed in plant premises.
Fire & Safety organization setup to be planned and implement for better plant
process safety.
Induction safety course to be prepared and trained all new employees before
starting duties in plant.

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