“Annexure- Document of Risk Assessment”
M/S. ZUARI AGRO CHEMICALS LTD.
EIA & EMP FOR CUSTOMIZED NPK
FERTILIZERS UNIT, GT, HRSG, AAST
& UREA GRANULATION UNIT
7
ADDITIONAL STUDIES
7.1
RISK ASSESSMENT
7.1.1
Introduction
CH-7: ADDITIONAL STUDIES
ZACL propose to implement a modernization project for revamping of liquid ammonia storage by
replacement of the existing Horton spheres by a double wall type atmospheric pressure storage
tank with superior safety features.
7.1.2
Scope & Methodology
Scope of this Quantitative Risk Assessment (QRA) study of 1X5000 MT capacity is to assess the
risk due to the proposed double wall type atmospheric pressure ammonia tank in place of existing
Horton spheres have capacity of 2X 3000 MT and suggest measures to reduce the risk to levels as
low as reasonably practicable.
This QRA study is carried out using the renowned DNV Phast Risk (also known as Safeti) software
package.
Risk due to a hazard is measured by considering severity level of the consequence as well as
likelihood of its occurrence. The general criteria for risk acceptance are as follows:


Individual risk exceeding 1 x 10(-)4 per year is not tolerable;
Individual risk below 1 x 10(-)6 per year is broadly acceptable;
 Individual risk between the above two levels is tolerable if it is demonstrated to be as low as
reasonably practicable (ALARP).
7.1.3
Facility Description
The details of liquid ammonia storage are summarized in Table 7-1.
Table 7-1: Details of Existing and Proposed Liquid Ammonia Tanks
Description
No. of Tanks &
Capacity of Each (MT)
Total Capacity
(MT)
Temperature
(C)
Pressure
(kg/cm2g)
2 x 3,000
6,000
5
4
1 x 5,000
5,000
(-)33
450- 900
mm WCg
Existing
Horton Spheres
Proposed
Wall
Type
Double
Atmospheric Pressure Tank
7.1.4
Details of Proposed Atmospheric Pressure Liquid Ammonia Storage
Liquid Ammonia received from road tankers & from Ammonia Plant will be stored in an
Atmospheric Ammonia Storage Tank having a net effective capacity to store 5,000 MT of liquid
Ammonia excluding vapor space. The outer tank is designed for full containment of vapors and
liquid in the event of failure of inner tank.
The tank is equipped with two pressure relief valves to safeguard against overpressure. (Isolation
valves will be provided with suitable mechanical interlock).
The tank shall rest on elevated foundation. Tank pressure is maintained between 450-900 mm
WCg and adequate alarms and interlocks are provided to safeguard the tank against pressure
excursions on either side of the operating range.
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CH-7: ADDITIONAL STUDIES
Refrigeration System
Liquid Ammonia, at a maximum rate of 90 MT/hr, is received from the tanker unloading line
through a 8” line and at a rate of 45 MT/hr through 6” line from existing Ammonia plant line with
suitable tapping taken at Battery limit (B/L) near the tank. Vapors from flashing and boil off are
withdrawn by two Ammonia Refrigeration Screw Compressors. The gas is compressed and
condensed in water cooled condensers and sent to the Ammonia Receiver.
Liquid is withdrawn from the Receiver under level control. A part of this liquid is flashed in the
Economizer, which operates at a pressure of approximately 1.5 Kg/cm2g. Flashed Ammonia vapors
at about -15°C are admitted into the Economizer port of the Screw Compressors. The balance
liquid Ammonia from the Receiver gets cooled to about – 10°C in the Economizer by the resultant
chill from the above described flashing and is returned back to the storage tank.
Transfer of Liquid Ammonia
Liquid ammonia from tank will be transferred at the rate of 46 m3/h to NPK A/B plants by using
the ammonia transfer pumps and existing ammonia preheater.
Flare System
A Hot Flare system shall be provided for the Ammonia tank (for emergency purposes). Thermal
relief valves are provided in sections of pipelines where liquid Ammonia can get blocked in.
Site map showing location of the existing Horton spheres and proposed atmospheric pressure tank
is presented in Figure 7-1.
Figure 7-1: Site Map Showing Existing and Proposed Liquid Ammonia Tanks
Proposed Atmospheric
Pressure Ammonia
Tank
Existing Horton
Spheres
7.1.5
Input Data for QRA
Weather data
Weather data for site used in risk analysis is listed in Table 7-2.
Table 7-2: Weather Data for Goa
Month
January
Temperature (C)
31.2
21.5
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Relative Humidity (%)
69
61
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Month
CH-7: ADDITIONAL STUDIES
Relative Humidity (%)
Temperature (C)
February
30.7
22.2
72
65
March
31.5
24.3
75
69
April
32.4
26.3
74
70
May
32.6
26.9
75
72
June
30.2
24.9
86
83
July
28.9
24.2
86
86
August
28.6
24.1
89
86
September
29.5
24.1
87
83
October
31.4
24.5
80
76
November
32.7
23.5
66
65
December
32.4
22.5
63
61
Wind rose diagram showing annual distribution of wind direction and wind velocity is shown in
Figure 3-2, Chapter 3.
Generic Failure Rate Data
This QRA study is based on generic failure rate data as available in the following publications.
OGP Risk Assessment Data Directory Report No. 434-3: Storage Incident Frequencies published by
International Association of Oil & Gas Producers.
Guidelines for Quantitative Risk Assessment “Purple Book” – Doc. No. CPR 18E.
The input data for QRA including the estimated failure rates is shown in Table 7-3.
Table 7-3: Failure case data for QRA
S.
No.
Description
A
Leak Size
Material
& Phase
Temperature
Pressure
(C)
(kg/cm2g)
Leak
Frequency
(per year)
Existing Horton Spheres for Ammonia Storage (2 Nos.)
1
Ammonia
Tank failure
Catastrophic
Failure
Liquid
Ammonia
5
4
1.0E-06
(each tank)
2
Liquid outlet
pipe failure
Line Rupture
Liquid
Ammonia
5
4 (+ Liquid head in
tank)
1.0E-05
(each tank)
B
Proposed Atmospheric Ammonia Storage Tank (1 No.)
1
Ammonia
Tank failure
Catastrophic
Failure
Liquid
Ammonia
(-)33
450-900 mm WCg
2.5E-08
2
Liquid outlet
pipe failure
Line Rupture
Liquid
Ammonia
(-)33
400 mm WG (+
Liquid head in tank)
1.0E-05
Note: 1.0E-06 per year denotes 1.0 x 10(-)6 per year
7.1.6
Study Results
Consequence Analysis Results
Results of consequence analysis by Phast software for leak from 100 mm diameter hole are
summarized in Table 7-4.
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CH-7: ADDITIONAL STUDIES
Table 7-4: Consequence Analysis Results
Down Wind Distance (Meters)
Description
Weather 
2 m/s; E
3 m/s; D
5 m/s; D
Parameter
Horton Sphere:
Liquid ammonia leak
– 100 mm size
IDLH: 300 ppm ammonia
4439
3101
2709
ERPG-3: 750 ppm ammonia
1959
1629
1424
Atmospheric Pressure Tank:
Liquid ammonia leak
– 100 mm size
IDLH: 300 ppm ammonia
1705
890
753
ERPG-3: 750 ppm ammonia
860
422
380
It is seen that the downwind distances for toxic dispersion of ammonia in case of leak are much
less in case of atmospheric ammonia tank compared to Horton sphere.
Horton sphere is semi-refrigerated type storage in which liquid ammonia is stored at about 4
kg/cm2g pressure and 5C temperature. Release of liquid ammonia under pressure by leak from
Horton sphere will cause much flashing of vapor due to depressurization and formation of liquid
droplets which will be carried over in the air. This will result in ammonia vapor dispersion over
long distance.
In contrast atmospheric tank is fully refrigerated type storage in which liquid ammonia is stored
close to atmospheric pressure at (-)33C temperature. In case of release of liquid ammonia by
leak from atmospheric tank there will be very little flashing of vapor. The dispersion will be mainly
due to vaporization of liquid ammonia falling on the ground close to the tank.
QRA Results
Results of QRA are presented in the form of iso-risk contours for individual risk.
The iso-risk contours for location-specific individual risk due to the two horton spheres in the
existing facility are shown in Figure 7-2.
Figure 7-2: Is-Risk Contours – Existing Horton Spheres (2 Nos.)
1E-06/year
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CH-7: ADDITIONAL STUDIES
The location-specific individual risk at eastern boundary of the plant near the Horton Sphere area
is found to be 3E-06 per year.
The iso-risk contours for location-specific individual risk due to the proposed atmospheric ammonia
tank are shown in Figure 7-3.
Figure 7-3: Is-Risk Contours – Proposed Atmospheric Ammonia Tank (1 No.)
1E-06/year
1E-07/year
The location-specific individual risk at the plant boundary near the proposed atmospheric ammonia
tank area is found to be within 1E-07 per year.
Conclusions
The conclusions of QRA study for ammonia storage at ZACL, Goa comparing the existing Horton
spheres and proposed double wall double integrity type atmospheric tank are as follows.
In the double wall double integrity tank, the inner tank and outer tank each can contain the liquid
ammonia inventory safely. Therefore In comparison to Horton sphere, the likelihood of failure of
double wall double integrity tank is negligible. According to the best industry practice, double wall
double integrity tank has proven to be the safest mode of storage of liquid ammonia.
Results of QRA clearly indicate that the individual risk at plant boundary is very much reduced by
replacing the Horton spheres by atmospheric ammonia storage tanks.


Individual risk at plant boundary in case of Horton spheres: 3E-06 per year
Individual risk at plant boundary due to atmospheric tank: 1E-07 per year
Based on the above factors, it is concluded that replacement of the two Horton spheres each 3000
MT capacity with one double wall double integrity type atmospheric tank of 5000 MT capacity will
result in considerable reduction of risk and enhancement of safety. This also conforms to the best
industry practice for liquid ammonia storage.
Recommendations
While implementing the installation of double wall double integrity type atmospheric ammonia tank
the following points need attention.
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1.
2.
3.
4.
CH-7: ADDITIONAL STUDIES
Liquid ammonia product stored in the atmospheric ammonia tank should contain not less than
0.2% water to prevent stress corrosion cracking in low temperature carbon steel (LTCS)
plates of the tank.
Proper quality assurance/ quality control programme including positive material identification
(PMI) should be followed to ensure that only the material (plates, pipes, fittings, welding etc.)
conforming to the specifications are installed.
Safety instrumented system with adequate reliability/ redundancy should be provided for tank
overfill and overpressure protection based on safety integrity level (SIL) analysis.
While commissioning the tank due care should be taken for removal of air from the system by
purging with adequate quantity of nitrogen to prevent stress corrosion cracking due to
presence of oxygen.
7.2
ONSITE EMERGENCY MANAGEMENT PLAN
Name and Address of the Person Furnishing the Information
Telephone nos.
Particulars
Office
Residence
0832 2592418
0832 2592501
0832-2592549
0832-2592537
0832-2592602
0832-2592517
Factory Manager
Mr. Ranjit Singh Chugh
Chief Manufacturing Officer
Zurinagar, Goa- 403726
In charge Fire & Safety
Mr. G. S. Lotlikar
Chief Manager-Fire & Safety
Zuarinagar, Goa- 403726
In charge of Occupational Health
Dr. A.G. Vaidya
Deputy General Manager-Medical
Zuarinagar, Goa- 403726
Contact nos. In case of any emergency
FIRE STATION: 3992101, 3992622
SECURITY : 3992100, 3992603
OCCUPATIONAL HEALTH CENTRE : 3992102
EMERGENCY CONTROL CENTRE : 3992111, 8805060002
7.2.1
Introduction
Disaster is a major emergency which has the potential to cause serious injury or loss of life and /
or which tends to cause disruption inside or outside the works and requires the use of outside
resources. The emergency is termed "on-site" when it confines itself within the factory even
though it may require external help and "off-site" when the emergency extends outside the factory
premises. It is to be understood that if emergency occurs inside the plant and could not be
controlled, it may lead to an "off-site emergency". It is imperative that plant emergencies like fire,
explosions are by nature fast acting and the control system would normally be of prevention from
spreading, rescue and relief work. The planning for emergency will thus incorporate resources and
action for concentrating on evacuation, containment and relief work. On the other hand in case of
disaster due to toxic gases, the measures will be on long-term basis and will depend upon the
distance and weather condition. We have adopted an "ON-SITE EMERGENCY MANAGEMENT
PLAN" to instill confidence in employees and public to tackle any situation that may arise.
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CH-7: ADDITIONAL STUDIES
The plan complies with the legal responsibility of the Occupier of the Factory as per Section-41B
(4), 1948 and Rule 13 of the Goa Control of Industrial Major Accident Rules, 1991 and also under
Manufacture, Storage and Import of Hazardous Chemicals Rules, 1989 (MSIHC). It also complies
with the elements of the On-site Emergency Plan suggested in the Guidelines on the Chemical
(industrial) Disasters issued in May 2007 by National Disaster Management Authority, set up under
the Disaster Management Act, 2005.
The recommendations made by National Disaster Management Authority during mock drill
conducted on November 13, 2009 have also been implemented in this revision.
7.2.2
Key Personnel and their responsibilities
The Emergency Management Plan spells the transition from normal operation to emergency
operations and effective delegation of the authority from operations personnel to emergency
response personnel. An emergency response organization has been identified with appropriate
lines of authority and how the response management will take over. Each responder’s position in
the emergency organization, line of reporting, responsibilities and duties have been identified and
clearly defined.
7.2.3
Concept of Emergency Response Operation
During any emergency in the factory, the effectiveness of the plan depends upon how fast and
effective is the communication system among the responders and the other agencies involved in
handling emergency.
We have developed a communication system for 24-hour notification of the first responders and
other coordinators who will provide necessary direction and control. An “alternate” person is also
identified for each key position of the designated authority. The plan also includes a list of
alternate personnel for each emergency response and their contact number.
A procedure of a call to one person/agency who in turn calls one or more key individuals during
emergency is used so that all the levels in the organization are communicated.
7.2.4
Emergency organization
Command and control of an emergency condition encompasses the key management functions
necessary to ensure the health and safety of workers, as well as community living in the vicinity,.
In addition, the implementation of an Emergency Response Plan relies on a number of response
functions, which deals with different aspects of the emergency, with the most important ones
being:







Communication and coordination between coordinators;
Emergency Control system at Incident site & Emergency Control Centre;
Firefighting and Rescue;
Medical Services;
Security & traffic control;
Liaison with Govt. as well as external support agencies;
Administration (Transport, welfare).
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CH-7: ADDITIONAL STUDIES
Figure 7-4: Emergency Management Organization
7.2.5
List of Key Persons
S.
No.
Role
Location
1.
Overall in charge: (Chief Manufacturing Officer )
Alternate –CGM-CS /CGM-O
ECC
2
Chief Coordinator :Chief GM-Operations/GM-Manufacturing
Alternate –DGM-Concerned Plant
Site
3.
Maintenance Coordinator: DGM-Maintenance & Civil
Alternate – SM-Mechanical (Nitrogen)
Site
4.
Environment & Technical Coordinator: Head-Projects & TS
Alternate –CM-TS/ Dy.GM.-Prod (unaffected)
Site
5.
Medical Coordinator: SM-Medical
Alternate – Nurse on duty
6.
Site Coordinator: DGM- concerned Plant
Alternate – CM-concerned Plant
7.
Fire & Safety Coordinator: CM-Fire & Safety
Alternate – M-FS
Health Centre
Site
Site/ECC
One of the Officer from F&S will report to ECC depending upon availability.
8.
Security Coordinator: CM-HR&S
Alternate – Manager-Security (NISA)
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9.
Welfare Coordinator : Manager-HR
Alternate : SM-CSR&PR
ECC
10.
Communication Coordinator: Sr. Manager-PH
Alternate: Manager-Stores
ECC
11.
Incident Controller*: CM/SM/Mgr (concerned Plant)
Alternate – In charge (Concerned Plant)
Site
Other Key personnel’s
12.
DGM’s from Unaffected Plants
& CM’S from Unaffected Plants
DGM’s - ECC;
CM’s - as per the
instructions from
Chief Coordinator
* In charge of the concerned plant, shall rush to the site along with his team and take charge till
arrival of Site Coordinator. (Concerned Plant DGM).
7.2.6
Duties and responsibilities of key personnel
Overall In-charge
The Overall-in-charge has an overall responsibility for directing operations and calling outside help.
Chief Manufacturing Officer (CMO) will take charge as Overall in-Charge. During his absence, Chief
General Manager-CS (CGM-CS) /Chief General Manager-Operations (CGM-O)or will act as Overall
In-Charge. He will decide upon the activation of Emergency Control Centre (ECC) depending upon
the prevailing wind direction. If required, he can activate the Mobile Emergency Control Centre.
The ECC is allocated next to Fire Station while alternate ECC is located at DAP gate. Overall inCharge will rush to ECC and perform roles/responsibilities as under.
1.
2.
3.
Continually review and assess existing & possible developments to determine the most
probable course of events and effective methods to deal with them;
Ensure that casualties are receiving adequate attention;
Decide in consultation with Chief Coordinator & key persons whether an off-site emergency
exists or is likely to take place. If an off-site emergency exists;
o
o
o
o
o
4.
5.
6.
7.
To alert evacuate the public living in the vicinity of the plant;
Call the outside emergency services;
Inform district emergency authorities;
Coordinate with district emergency authorities to mitigate the consequences outside the
factory;
Coordinate with District Emergency Authorities for evacuation, shelter, rescue &
rehabilitation of general public in the vicinity of affected area.
Issue authorized statements to the press or the media;
Inform MD regarding the status and action taken;
Rehabilitate the affected area after the emergency is over;
In case of strike by the plant personnel, identify critical areas of the plant in advance. If
emergency occurs during the strike, following arrangements required to be made in advance;
o
o
o
Keep the list of technical records needed to run the factory in an emergency and train the
team.
Keep the records of Personnel (Non-executive) likely to be available during the strike and
keep the same in safe custody.
Identify the alternate arrangements for meeting any emergency, ie by mutual aid with
other factories, etc.
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Chief Coordinator
Chief General Manager-Operations (CGM-O)/General Manager- Manufacturing (GM-M) will act as
Chief Coordinator. Deputy General Manager (DGM)-of the Concerned Plant will act as alternate in
case of absence of CGM-O/GM-M. The senior most available i.e. Plant in charge (Chief
Manager/Sr. Manager) or Shift In-charge for that shift will work as Site Coordinator till the arrival
of seniors in case the emergency occurs after Office hours or on holidays,.
After getting information about the emergency from the shift-in-charge/CM-concerned or on
hearing emergency, he will inform Chief General Manager-Operations who in turn will inform Chief
Manufacturing Officer (CMO). Chief Coordinator will report to the incident site and will operate
from the location nearest to the site.
The responsibilities are as follows:
1.
To assess the magnitude of the situation and decide whether a major emergency exists or it is
likely to convert into a major emergency, requiring external assistance. He will instruct to
sound the coded emergency siren;
2. To exercise direct operational control over the areas other than those affected;
3. To communicate to Asst. Manager–Environment to monitor the environment for toxic gases
and effluent;
4. After assessing the magnitude of the situation, he will decide whether the persons inside the
factory are to be evacuated to pre-identified safe places;
5. To have a constant liaison with the authorized coordinators for ensuring that the casualties
are receiving adequate attention and traffic control movements within the works is well
regulated;
6. To communicate about the emergency to higher ups;
7. To arrange to inform Chief Inspector of Factories, District Collector, Police, Village Sarpanch,
Goa State Pollution Control Board, Fire Brigade, (Vasco-da-Gama) if required through
Communication Coordinator;
8. To arrange for collecting and preservations of evidences to facilitate any enquiry into the
causes and circumstances which cause or escalated the emergency. He shall arrange for the
photographs, video filming, logbooks, operating charts etc.;
9. To make assessment of total no. of casualties, damage incurred to plant, Property and
machinery and damage to environment during emergency;
10. After establishing normalcy from Emergency, Health Centre and other plants, he will authorise
to sound ALL-CLEAR SIREN.
Site Coordinator
Deputy General Manager of the concerned Plant would be Site Coordinator. In his absence Chief
Manager/Sr. Manager of the concerned plant will take charge as Site Coordinator.
1.
After getting information about the emergency from the shift-in-charge/CM-concerned or on
hearing emergency he will inform:
o
o
o
2.
GM-M;
DGM’s unaffected plant;
CM’s of other plants reporting to him.
He will report to the incident site and take over charge from the shift-in-charge and work
under Chief Coordinator;
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3.
4.
5.
6.
7.
8.
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CH-7: ADDITIONAL STUDIES
He will assess the extent of emergency and decide if a major emergency exists or is likely to
develop and also to decide to summon help if so required in consultation with Chief
Coordinator;
To take the command of the emergency at site, and co-ordinate all activities to bring situation
under control within shortest possible time. He will coordinate with the concerned Chief
Manager’s regarding shutting down of the plant, if required;
To coordinate with Maintenance Coordinator, Fire & Safety Coordinator for the help;
To ensure that the emergency is curtailed to cause minimum loss to the persons, machine and
environment;
To decide evacuation of plant personnel of the areas likely to be affected;
Make sure that all hot jobs have been stopped and assist Manager/Shift-in-charges in
normalizing the emergency.
Maintenance Coordinator
Dy. General Manager-Maintenance & Civil will act as Maintenance Coordinator. In his absence, Sr.
Manager-Mechanical (Nitrogen) will act as Maintenance Coordinator.
1.
After getting information from the concerned ECC or Chief Manager/Sr. Manager or on hearing
siren he will inform:
o
o
o
o
2.
3.
4.
5.
6.
7.
Sr. Manager’s-Mechanical;
Sr. Manager-Central Maintenance (Mech);
Manager-Civil;
Centralised Shift Office.
To rush to the site, assess the situation and facilitate maintenance support to Chief
coordinator, needed to tackle the emergency;
To mobilise and coordinate the teams from Maintenance Department for isolation,
disconnection of equipment making bunds, repair activities, to control / mitigate effects of the
emergency;
To arrange for isolation of electrical lines (if required), facilitate lighting arrangements at
affected locations, assembly points. Chief Manager-Electrical and his team will assist
Maintenance Coordinator;
To arrange earth moving equipments like Cranes etc. (if required) for handling the
emergency;
To arrange workshop facilities with adequate manpower (if required);
To arrange for emergency procurement of material from local dealers or from other industries,
additional manpower (contract) through Purchase.
Environment and Technical Coordinator
Head- Projects & Technical Services (H-P&TS) will act as Environmental and Technical
Coordinator. His Alternate will be Chief Manager -Technical Services (CM-TS). After General Shift
hours and/or Holidays, one of the Dy. GM- Plant of unaffected plant will take the charge of
Environment and Technical Coordinator in absence of H-P&TS/CM-TS.
After getting information from Emergency Control Centre or on hearing Emergency Siren, he will
inform;
o
o
o
o
CM-TS
CM-Projects
CM-Inspection
Stores in charge
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1.
2.
3.
4.
5.
6.
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CH-7: ADDITIONAL STUDIES
Rush to the incident site and identify the hazards.
Facilitate monitoring/analysis of the area inside and outside the factory premises (if required)
through laboratory in charge and keep Chief Coordinator informed about the results;
Remain in touch with the site coordinator and shift-in-charge for taking samples and rendering
help for plant personnel;
Inform the concentration of toxic gases to Overall in Charge and Chief coordinator and
Medical Coordinator;
Arrange for analysis of liquid effluent discharge from the factory if any;
Maintain record of base data and the conditions prevailing during emergency.
Fire & Safety Coordinator
Chief Manager-Fire & Safety (CM-F&S) will act as Fire & Safety Coordinator. In his absence,
Manager-Fire & Safety (M-FS) will act as Safety Coordinator.
After getting information from ECC or on hearing Emergency Siren, he will inform Manager-Fire &
Safety
He will report to the scene of emergency and perform the duties and responsibilities as follows:
1.
2.
3.
4.
5.
To take charge of fire fighting responsibility under the guidance of Chief Coordinator;
To arrange for additional firefighting equipment/material like hoses, branch pipes, fire
extinguishers, foam compound, fire suits, breathing apparatus etc;
To advise Chief Coordinator regarding external help and direct outside fire fighting services
whenever called for;
To assist the employees in the rescue operation & use of safety appliances;
To brief Chief Coordinator about overall emergency and safety procedures followed during the
emergency.
Security Coordinator
Chief Manager-HR & S (CM-HR&S) will act as Security Coordinator. In his absence, ManagerSecurity (NISA) will act as Security Coordinator.
After getting information from Main Gate House or on hearing Emergency Siren, he will inform;
o
o
1.
2.
3.
4.
5.
6.
7.
8.
9.
CGM-CS
M-HR
Rush to the Incident Site and report to Chief Coordinator;
Control the traffic movement in and out of the factory. This involves both movements of
vehicles and the persons;
Maintain Law and Order and to avoid gathering of personnel at the scene of emergency.
Cordon off the affected area;
Provide assistance to Fire & Safety Coordinator for firefighting or for removing the casualties
or supply of safety appliances etc.;
Keep liaison with Police;
Direct external help from local authorities to respective coordinators;
He will be responsible for public announcement of the hazards and action to be taken on
Public Address System;
Arrange for vehicles from outside local transport agencies in case of need;
Assist Site Coordinator, Medical Coordinator, Fire & Safety Coordinator for the transportation
of victims from the affected area to safe places.
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EIA & EMP FOR CUSTOMIZED NPK
FERTILIZERS UNIT, GT, HRSG, AAST
& UREA GRANULATION UNIT
CH-7: ADDITIONAL STUDIES
Medical Coordinator
Sr. Manager-Medical (SM-M) will act as Medical Coordinator. In his absence, the Male Nurse on
duty at the Health Centre will act as Medical Coordinator.
On getting information from Health Centre, he will rush to the Health Centre and perform the
duties and responsibilities as follows:
1.
2.
3.
4.
5.
6.
Call the trained First Aiders from the unaffected plants/township;
Arrange for additional doctor (if required) and ambulances;
Have liaison with local medical authorities and hospitals in case the casualties are more and
situation demands treatment from additional Medical Centres;
Ensure the up-keep of medical supplies, antidotes for treating victims for burns and hazardous
chemicals;
Remain in touch with Overall-In charge and Chief Coordinator for any help required;
Liaison with Security Coordinator for the transportation of the injured to the Hospitals.
Communication Coordinator
Sr. Manager-Product Handling (SM-PH) will act as Communication Coordinator. In his absence
Manager-Stores (M-S) will work as Communication Coordinator.
After getting information from ECC or on hearing Emergency Siren, he will rush to Emergency
Control Centre and report to Overall In-charge;
1.
2.
3.
4.
Take charge of communication through telephones, messengers, Walkie-talkie sets etc.;
Arrange for announcements on public address system and maintain contacts with Canteen,
Main Gate, Control Room, Fire Station etc;
Maintain a log of major emergency with timings about the various communications received /
passed from the Emergency Control Centre;
Seek help/assistance from the other coordinators reporting to ECC in case of need.
Welfare Coordinator
Manager-HR will act as Welfare Coordinator. In his absence Sr. Manager-CSR & PR will act as
Welfare Coordinator.
After getting information from Security Coordinator or on hearing Emergency Siren, he will inform;
o
o
CGM-HR
SM- CSR & PR
He will rush to Emergency Control Centre and report to Overall In-charge;
1.
2.
3.
4.
5.
6.
Arrange for supply of food and beverages to emergency fighting crew both from inside and
outside agencies as and when required;
Arrange for supply of food and other necessary items to injured and affected persons;
Intimate about the casualties to the relatives of the injured persons;
Keeps record of attendance of emergency fighting crews and exact number of people inside
the factory;
Assess the situation in the surrounding areas;
Evacuate colony and affected areas and make arrangement for shifting them to alternate safe
places, if required.
KADAM ENVIRONMENTAL CONSULTANTS | SEPTEMBER 2016
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7.2.7
EIA & EMP FOR CUSTOMIZED NPK
FERTILIZERS UNIT, GT, HRSG, AAST
& UREA GRANULATION UNIT
CH-7: ADDITIONAL STUDIES
Responsibilities of the key persons during emergency
Shift-in-charge (Concerned Plant)
1.
Proceed to the emergency site, assess the situation and inform;
o
o
2.
3.
4.
5.
Fire Station /Emergency Control Centre (101, 2622, 111) giving the details, type of
emergency;
Inform Chief Manager/GM-M.
Till the arrival of the designated Chief Coordinator act as Chief Coordinator;
Initiate the control operations for controlling the hazards;
Do not allow any person to enter the area without required PPE’s;
Direct rescue operations with the help of fire, Safety & Security staff;
Civil Coordinator: (Sr. Manager-Civil/Manager -Civil)
1.
2.
3.
Rush to the scene of the emergency after getting information from Maintenance Coordinator
or on hearing emergency siren;
Mobilize contractors, contract workers and heavy earth moving equipment to carry out civil
jobs like making bunds, closing drains, filling sand bags, excavation as per the requirements
during the emergency;
Be available at the incident site and constant in touch with Maintenance Coordinator and Site
Coordinator.
Public Relations Coordinator: (Sr. Manager-CSR & PR)
1.
2.
3.
On getting information from Welfare Coordinator or on hearing emergency siren, he will report
to Emergency Control Centre. He will work directly under Overall In-Charge;
He will also carry out the role of Welfare Coordinator in absence of M-HR;
He will release the authorized information, statements from CMO to the media & Press.
Essential Staff




Plant Technicians and plant staff shall remain in the plant and take the corrective action,
safe shutdown action depending upon the instructions/directions from the concerned sectional
heads and superiors. The maintenance staff of respective plants will be available at the plant
and will work under instructions from shift-in-charge/plant in charge/maintenance in charge;
Trained First Aiders of the respective plant/sections shall reach the incident Site and render
First Aid till assistance from Health Centre arrives and thereafter assist the Medical Team. The
trained first Aiders from non plant areas should report on hearing emergency siren or on call
from Medical coordinator and follow instructions from him;
Trained Fire Fighters of the effected site (including those of service Dept) shall reach the
incident site to help the Fire Fighting and mitigating the emergency. They shall remain at site
to assist the fire fighting and follow the instructions/directions from Fire & Safety Coordinator.
The trained fire fighters from other unaffected plants/sections should get in touch with ECC;
The Security Guards in their respective posts within the factory and at other posts shall not
allow any unauthorized entry or person. They shall properly guide Goa Fire & Emergency
Services, Mutual Aid Group and other external authorities whenever called for to the incident
site. They will keep inform about any abnormal movements/activity to the Security
Coordinator/Main Gate.
KADAM ENVIRONMENTAL CONSULTANTS | SEPTEMBER 2016
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7.2.8
EIA & EMP FOR CUSTOMIZED NPK
FERTILIZERS UNIT, GT, HRSG, AAST
& UREA GRANULATION UNIT
CH-7: ADDITIONAL STUDIES
Actions by the other persons present
On hearing emergency siren, all the persons who are not a part of response teams would
immediately evacuate their place of work and proceed to the nearest Assembly Point. The
concerned officers will be responsible to evacuate the visitor to the Assembly Point.
Locations of the Assembly Points along with in-charges are as under:





Assembly
Point
Location
Person Assembling
In charge
AP-1
Ammonia/Urea
Ammonia/Urea Operation Staff
Ammonia Shift
Manager
AP-2
Power Station
Power Station Operation Staff
Shift Manager
AP-3
Water
Treatment
Water Treatment Operation Staff
Shift Manager
AP-4
NPK-A
Operation staff & Contract Staff
Shift Manager
AP-5
NPK-B
Operation staff & Contract Staff
Shift Manager
AP-6
NPK-A & B
maintenance
office
Field maintenance staff of NPK-A & B & contract
staff
ManagerMechanical
AP-7
PH Office
Operation Staff & Field maintenance PH/RMH
Shift Manager
AP-8
Passage in front
of instrument
dept.
Laboratory, Instrument workshop, electrical
workshop & mechanical workshop , Stores,
maintenance office staff
ManagerInstruments
AP-9
Near Fire Station
Works Office Staff , Tanker crew of furnace oil &
Ammonia, Visitors and Works Canteen Staff
ECC coordinator
AP-10
Behind
DAP/Bagging
Phosphoric acid, Sulphuric acid tanker crew,
Stacking & unshackling gangs of monsoon shade,
Contract bagging staff & Labour canteen
NEHA foreman
AP-11
In front of Jai
Kisaan Bhawan
For Administration Staff, SBI staff , drivers and
Adm. Visitors
M-HR/SM-P&IR
It is the responsibility of all job in charges to train the personnel including the contract staff
working under him as to how to assemble safely to the designated Assembly Point and to
listen and follow the instructions issued by the in-charges of the Assembly Point;
It is the responsibility of the Sr. Officials to direct the Visitors, service providers to assemble to
the nearest Assembly Point and follow the instructions;
It will be the responsibility of the concerned Assembly Point In-charge to shift the personnel
under his charge to the other Safest Assembly point depending upon the wind direction;
In case any person is suspected to be missing, the Assembly Point in Charge should inform
the Overall In-Charge and Chief Coordinator;
After “ALL CLEAR” siren, all Assembly point in-charges will report to ECC with the list of Roll
Call.
7.2.9
Outside organizations if involved in assisting during On-site Emergency
In case any emergency going out of control and requires any external help, the same will be
decided by the Overall In-Charge in consultation with the Chief Coordinator. The communication to
these external agencies will be made by Communication Coordinator from ECC. Either Chief
Manager-Fire & Safety/Manager-Fire & Safety/Fire & Safety Officer will assist the Communication
Coordinator in this communication.
KADAM ENVIRONMENTAL CONSULTANTS | SEPTEMBER 2016
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7.2.10
EIA & EMP FOR CUSTOMIZED NPK
FERTILIZERS UNIT, GT, HRSG, AAST
& UREA GRANULATION UNIT
CH-7: ADDITIONAL STUDIES
Statutory bodies and their addresses
S. No.
Statutory bodies
1
Telephone
Fax
Inspectorate of factories & boilers
a.
b.
c.
Chief Inspector of Factories & Boilers
Institute of Occupational Safety, Health
& Environment,
Altinho, Panaji-Goa
2227670,
2226181
2226510
Inspector of Factories
Institute of Occupational Safety, Health
& Environment,
Altinho, Panaji-Goa
2226181
2226510
Inspector of Boilers
Institute of Occupational Safety, Health
& Environment,
Altinho, Panaji-Goa
2226181
2226510
Goa State Pollution Control Board
2
a.
Chairman
Goa State Pollution Control Board
Patto Plaza
Panjim-Goa
2438563
2438528
b.
Member Secretary
Goa State Pollution Control Board
Patto Plaza
Panjim-Goa
2438563
2438528
3
Dept. of Explosives
a.
Chief Controller of Explosives
Dept. of Explosives, C.G.O. Complex
5th Floor, Seminary Hills,
Nagpur-440 006, MAHARASHTRA
(0712) 2510248,
2510579
b.
Joint Chief Controller of Explosives
A-1 & A-2 Wing, 5th Floor, C.G.O Complex
CBD, Belapur
Navi Mumbai (MAHARASHTRA) 400 614
(022) 27564941
List of Govt. Officials and their contact details
Contact Number
Designation of
Person
Office
Mobile
Residence
STATE GOVT. OFFICIALS
Chief Secretary
2419402
-
-
Collector-North Goa
2223612
9822123071
2420710
Collector-South Goa
2705333
9423884900
-
Dy. Collector, Mormugao
2512688
9822588399
-
Supdt. of Police-North
2416100
-
Supdt. of Police-South
2732218
-
-
Dy. Supdt. of Police-Mormugao
2500222
-
-
PI, Verna police Station
2782325
-
-
PI, Vasco Police Station
2512304, 2513273
-
-
PI, Harbour Police Station
2520740
-
-
Director, Goa Fire& Emergency Services
2225500, 2227616
9763717044
2225033
KADAM ENVIRONMENTAL CONSULTANTS | SEPTEMBER 2016
209
EIA & EMP FOR CUSTOMIZED NPK
FERTILIZERS UNIT, GT, HRSG, AAST
& UREA GRANULATION UNIT
M/S. ZUARI AGRO CHEMICALS LTD.
CH-7: ADDITIONAL STUDIES
Contact Number
Designation of
Person
Office
Mobile
Residence
Station Fire Officer, Vasco
2513840
9763717056
-
Station Fire Officer, Verna
2887122
9763717060
-
Asst. Divisional Officer, Margao
2714600, 2715825
9763717052
-
Chief Inspector of Factories & Boilers
2227670, 2226181
9411440008
-
2404876
-
Inspector of Factories
MAJOR HOSPITALS
7.2.11
Goa Medical College
2458700, 2458702
-
-
SMRC
2540218, 6691919
-
-
MPT Hospital
2512768
-
-
Hospicio Hospital
2705754, 2704363
-
-
Details of Liaison Arrangement between the Organisations
Mutual aid and response group
Details of liaison arrangement between the mutual aid partners are worked out. Then an
agreement is signed between all the mutual aid partners. The agreement contains all the
procedures like communication, place of reporting, responsibilities and duties during the
emergency. The outside agencies from whom the assistance will be sought are Mormugao Port
Trust, Indian Navy, Goa Shipyard Ltd., Indian Coast Guard.
The mutual aid partners will be made aware of various types of hazards in each plant and the
existing fire fighting system.
Mock drills with mutual aid partners will also be carried out at regular intervals.
Telephone nos.
S.
No.
Name of contact person
1.
2.
Office
Residence
Central Fire Station-MPT
2521300, 2594812
2522690
Indian Coast Guard
2520584, 2521051
-
3.
Goa Shipyard Ltd.
2512152- 2512156
2540912
4.
Duty Staff Officer-Indian Navy
2582200
-
5.
Terminal Manager -IOC
2513067, 2512617
2521856
7.2.12
Preliminary Hazard Analysis
Type of Accident, system elements & Hazards
Type of Accident
System Elements or Event that can lead
to the Main Hazard
Hazard
Ammonia leakage




Ammonia Hortonshere
Process area
Transfer line
Ammonia Unloading Station


Toxic release
Fire Hazard
Spillage of Corrosive
chemicals




Acid storage: H2SO4, H3PO4
Alkali (NaOH) storage
Process lines
Acid, caustic unloading area


Acid and alkali burns
Acid spills in small,
medium and large
quantities
Spillage and Fire


HSD storage
Oil console in process area/compressor
KADAM ENVIRONMENTAL CONSULTANTS | SEPTEMBER 2016
Pool Fire
Fire Hazard
210
M/S. ZUARI AGRO CHEMICALS LTD.
Type of Accident
EIA & EMP FOR CUSTOMIZED NPK
FERTILIZERS UNIT, GT, HRSG, AAST
& UREA GRANULATION UNIT
CH-7: ADDITIONAL STUDIES
System Elements or Event that can lead
to the Main Hazard
Hazard

Empty bag storage area in PH
Chlorine leaks


Chlorine tonners
Chlorine pipelines/manifolds

Toxic release
Fire & Explosion



Process area
GAIL metering station/terminal
Gas line from GAIL to process plants




Fire/pool fire
Flash fire explosion
VCE
Boiling Liquid Expanding
Vapour Explosion (BLEVE)

Boilers


BLEVE
High Pressure Component
Rupture
System Elements/Events that can lead to major accidents, hazard and safety related
components
Ammonia storage handling facility
Existing Horton sphere storage will be converted to Atmospheric Ammonia Storage Tank (Double
wall, Double Integrity tank) which is more safest technology to store Ammonia.
Chlorine storage and handling area
At ZACL, Chlorine is used in following three locations:



Water Treatment Plant
Cooling Tower-I
Cooling Tower-II
The following are the safety features incorporated:







Chlorine detector is provided to detect ant leak of Chlorine. These detectors generate an
alarm in the Water Treatment Control Room;
Chlorine emergency kit is provided at the Chlorine handling location;
Chlorine Absorption system is also provided which automatically will start on leakage of
Chlorine and will neutralize with NaOH solution;
Self Contained Breathing Apparatus and specialize suits for handling Chlorine are provided at
Chlorine Handling area;
Eye was and Safety Showers are provided;
PPPE’s like Protective clothing, gloves, face shield, goggles, canister gas masks are provided
for the persons handling Chlorine;
The trained technicians/employees are employed.
Boilers
The Boilers are designed and fabricated as per the relevant codes and standards and installed
after due approval from Chief Inspector of factories & Boilers, Goa.



All the boilers are offered to the Annual survey to the Inspector of Boilers;
Boilers have inbuilt Boiler Management System logic for safe and smooth normal operation,
start-up/shutdown;
Logic like conditions of purge ready to start, burner ready to start, tripping on Natural Gas,
tripping on furnace pressure, furnace pressure high, drum level low etc are incorporated in
the BMS logic;
KADAM ENVIRONMENTAL CONSULTANTS | SEPTEMBER 2016
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

EIA & EMP FOR CUSTOMIZED NPK
FERTILIZERS UNIT, GT, HRSG, AAST
& UREA GRANULATION UNIT
CH-7: ADDITIONAL STUDIES
Safety valves are provided at each Boiler drum and Super heater steam line;
Reliable instrumentation, including level gauges & transmitters are provided on each boiler.
HSD storage, Furnace oil Storage (both at power station), transformer areas and Oil
console







Adequate nos. of extinguishers are provided, tested and maintained;
Fire hydrant system is provided near and around the area;
Dykes are provided for HSD and Furnace Oil storage areas;
Manual Call Points are provided;
Sufficient nos. of sand buckets is provided;
The areas are maintained free from combustible materials;
Steam hoses are also provided near oil consoles.
Storage of corrosive liquids like sulphuric & phosphoric acid, caustic lye







Bunds walls/dyke are provided;
Level gauges with indication and alarm is provided;
Eye wash and safety showers are provided near to the storage and handling area;
Manual call points are available;
The floor area is made acid proof;
Caution boards and what to do in case of spill are displayed;
Full protective suits, gumboots, goggles, gloves, face shield are provided to the person
handling corrosive liquids.
Details about the Site
Location of dangerous substances
Ammonia
Ammonia is an intermediate product which is in liquid state and vapor state. Ammonia is used in
the manufacture of Urea and complex fertilizers. Ammonia is fed to the plants through pipelines
and stored in hortonsphere. The ammonia is used/processed and handled in Ammonia plant, Urea
Plant, NPK-A, NPK-B and RMH plants.
Storage: Ammonia is stored in Hortonsphere which is located near Ammonia Plant. One
hortonsphre is always kept stand by
Chlorine
Chlorine is used in the treatment of water at water treatment plant. It is available in the connected
piping and manifold in Water Treatment plant.
Storage: Chlorine tonners are kept in Water Treatment plant under covered storage.
Hydrogen
Hydrogen exists in gaseous intermediate for manufacturing Ammonia. It exists in the process gas
and is not stored.
Carbon Monoxide
Carbon monoxide exists as gaseous intermediate which then gets converted into carbon monoxide
with steam in shift converters and exists in Ammonia Plant.
KADAM ENVIRONMENTAL CONSULTANTS | SEPTEMBER 2016
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FERTILIZERS UNIT, GT, HRSG, AAST
& UREA GRANULATION UNIT
CH-7: ADDITIONAL STUDIES
Phosphoric acid
Phosphoric acid is used as a raw material in NPK-A & NPK-B Plant. It exists in pipelines and
process equipment.
Storage: It is stored in tanks and day tanks in RMH, NPK-A & NPK-B plants.
High Speed Diesel (HSD)
HSD is used as a fuel for initial start up of Boilers, diesel generator is a fuel used for emergency
generator.
Storage: It is stored in tanks located at Power station
Sulphuric acid
Sulphuric acid is used as raw material for production of complex fertilizers and also for water
treatment. It is available in pipelines connected from storage tanks to the process equipment in
NPK-A, NPK-B, Water treatment and Utilities Plants.
Storage: It is stored in tanks located in NPK-A, NPK-B, RMH, Water Treatment and Utilities Plant.
Furnace oil
Furnace oil is used as a fuel in DG, NPK-A and NPK-B plants. It exists in pipelines connected from
day tanks to the boilers and furnaces.
Storage: Furnace oil is stored in storage tanks and day tanks located at Power Station, NPK-A
and NPK-B plants.
Caustic Lye (Sodium hydroxide)
Caustic lye is used for water treatment. It exists in pipelines.
Storage: It is stored in tanks at Water Treatment Plant.
Natural Gas
Natural gas is used as feed material for Ammonia Production and also as fuel in Boilers, and NPK
Plant. It is supplied through a gas pipeline from GAIL Terminal.
7.2.13
Seat of Key Personnel
The location and seat of the Key personnel during normal operations and during emergency is as
follow:
S.
No.
During normal operation
During emergency
Designation
Location
Coordinator
Location
1
Chief Manufacturing
Officer
Admn. Block/B-Colony
Overall In-charge
Alternate –CGM-CS/ CGM-O
ECC
2
CGM-O/GM-M
Admn. Block/ Work
Office/B-Colony
Chief Coordinator
Alternate –DGM-Concerned
Site
3
DGM-Maintenance &
Civil
Maint. Office/ C-Colony
Maintenance Coordinator
Alternate –SM-Mech.
Site
4
Head-Projects & TS
Works Office /
B-Colony
Environment & Technical
Coordinator
Alternate –CM-TS/Dy.GM.-Prod
(unaffected)
Site
5
SM-Medical
Health Centre
/C-Colony
Medical Coordinator Alternate –
Nurse on duty:
Health
Centre
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S.
No.
EIA & EMP FOR CUSTOMIZED NPK
FERTILIZERS UNIT, GT, HRSG, AAST
& UREA GRANULATION UNIT
During normal operation
CH-7: ADDITIONAL STUDIES
During emergency
Designation
Location
Coordinator
Location
6
DGMconcerned Plant
Works Office/
C-Colony
Site Coordinator
Alternate – CM-concerned Plant
Site
7
CM-Fire & Safety
Work Office/C-Colony
Fire & Safety Coordinator
Alternate – M-FS
Site/ECC
8
CM-HR&S
Admn. Block/ C-Colony
Security Coordinator Alternate –
Manager-Security (NISA)
Site
9
M-HR
Admn. Block/ D-Colony
Welfare Coordinator Alternate :
SM-CSR & PR
ECC
10
SM-PH (ISM)
PH/ C-Colony
Communication Coordinator
Alternate: Manager-Stores
ECC
11
CM/SM/Mgr (concerned
Plant)
Plant
Incident Controller
Alternate – In charge
(Concerned Plant)
Site
12
DGM’s from Unaffected
Plants
Plant/ C-Colony
-
ECC
13
CM’S from Unaffected
Plants
Plant/ C-Colony
-
ECC
7.2.14
Emergency Control Centre
Two emergency Control Centres are set up:


Emergency Control Centre. (Alternate control centre at DAP gate). In case both the ECC are
not suitable, a mobile ECC in Emergency Rescue vehicle can also be set up;
Incident control room.
Location of ECC
Fire station is identified as Emergency Control Centre. The Control Centre will be the focal point in
case of emergency from where the overall operation to handle the emergency is directed and
coordinated. In case of adverse wind direction affecting the Emergency Control Centre, Emergency
Rescue Vehicle will be converted into Mobile Emergency Control Centre for this purpose. At all
Emergency Control Centers i.e. Fire Station, DAP gate and Mobile Centre the following information
is available.
Facilities available at ECC









Lay out plan of the complex, indicating all the plants, emergency control centre, roads, escape
routes, health centre, fire station, location of fire water pumps and highlighting hazardous
areas, location of wind socks, ammonia leak detectors;
List of fire fighting and safety equipment;
Population distribution map of surrounding area up to 10 km radius;
Copy of on-site emergency management plan;
List of telephone numbers of key personnel;
List of important telephone numbers like members of mutual aid scheme, fire brigade, police
station, District Collector's office, Chief Inspector's office, etc.;
Self Contained breathing sets (2 nos.), Explosive meter (1 no.), safety torches (2 nos.),
chemical suit (1 no.);
Walkie-talkie sets and Base station (set.);
Office facilities including internal telephones /external (3 nos.), Mobile phone (1 no) chairs,
table, stationary, etc.
KADAM ENVIRONMENTAL CONSULTANTS | SEPTEMBER 2016
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EIA & EMP FOR CUSTOMIZED NPK
FERTILIZERS UNIT, GT, HRSG, AAST
& UREA GRANULATION UNIT
CH-7: ADDITIONAL STUDIES
Manning of ECC during Emergency
During any emergency, ECC will be manned by the following personnel:
Overall In-Charge and his alternate;
Communication Coordinator and his Alternate;
Welfare Coordinators and his Alternate;
Other Key Personnel like Dy. GM’s of unaffected plant, Public Relation Coordinator.




7.2.15
Description of Hazardous Chemicals at Plant Site
Chemicals (Quantities, Purity and Toxicological data)
Details of Chemicals in process
Hydrogen
Hydrogen is in gaseous intermediate for manufacture of Ammonia. This is produced and is not
stored. It is one of the constituent for manufacturer of Ammonia.
Carbon monoxide
Carbon Monoxide is a gaseous intermediate. This gets converted into CO2 with steam.
Details of Chemicals in storage
S.
No.
Name of
chemical
Toxicity
Total Licensed/
Storage
capacity
No of
tanks/
storages
Purity of
chemical
Whether
transformation
could occur
1
Ammonia
Toxic
5600 MT
2
99.6-99.8
No
2
Chlorine
Toxic
6 Tonners
6
99.9
No
3
Phosphoric acid
Corrosive
13264 MT
5
52-54%
No
4
Caustic Lye
Corrosive
56 MT
2
46%
No
5
Sulphuric acid
Corrosive
3107 MT
6
98-99%
No
6
High speed diesel
Flammable
24.8 KL
2
-
No
7
Furnace oil
Flammable
314 KL
7
100% liquid
No
8
Process gases
Flammable
-
-
Varies
No
Likely Dangers to the Plant
Risk assessment study has been carried out in April 2009 through NEERI, Nagpur with the aim to
estimate the distances likely to be affected in case of Ammonia release and impacts of fire. The
scenarios considered are summarized below with the following assumptions:
Stability Class F with wind speed 2 m/s and for class D with 3 m/s;
IDLH for Ammonia: 300 ppm.


Toxic/pool fire/jet fire/flash fire
TOXIC
1.
Ammonia storage tank
Leak size 25 mm diameter
Source strength 0.38 Kg/sec
Toxic
cloud
At stability class 2F: distance 261 m
At stability Class 3D: distance=235 m
2.
Ammonia storage tank
Leak size 50 mm diameter
Source strength 1.52 Kg/sec
Toxic
cloud
At stability class 2 F: distance 394 m
At stability Class 3 D:distance=470 m
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Pool fire/Jet fire vapour cloud explosion/flash fire
3.
Natural gas pipeline
Pressure: 40 Kg/cm2g
Flow rate: 1.65 MSCMD
Leak size 25 mm, Source strength
2.96 kg/sec
Flash
fire
At stability class 2F
LFL distance-15.83 m
At stability Class 3D
LFL distance-14.90 m
4.
Natural gas pipeline
Pressure: 40 Kg/cm2g
Flow rate: 1.65 MSCMD
Leak size 50 mm, Source strength
11.8 kg/sec
Flash
fire
At stability class 2F
LFL distance-41.18 m
At stability Class 3D
LFL distance-38.42 m
5.
Natural gas pipeline
Pressure: 40 Kg/cm2g
Flow rate: 1.65 MSCMD
Catastrophic rupture, Source
strength 86.35 kg/sec
Flash
fire
At stability class 2F
LFL distance-133.27 m
At stability Class 3D
LFL distance-123.34 m
6.
Ammonia storage tank
Temp: 4 deg, C
Pressure: 4 kg/cm2g
Capacity 3000 MT
VCE
At stability class 2F
bar, damage distance 901.65 m
At stability class 3D,
0.1 bar, distance-893 m
7.
Natural gas pipeline
Pressure: 40 kg/cm2g
Flow rate: 1.65 MSCMD
Leak size: 25 mm
Source strength 2.96 Kg/sec
VCE
At stability class 2F
bar, damage distance 49.43 m
At stability class 3D,
0.1 bar, distance-38.79 m
8.
Natural gas pipeline
Pressure: 40 kg/cm2g
Flow rate: 1.65 MSCMD
Leak size: 50 mm
Source strength: 11.8 Kg/sec
VCE
At stability class 2F
bar, damage distance 113.6 m
At stability class 3D,
0.1 bar, distance-101.18m
9.
Natural gas pipeline
Pressure: 40 kg/cm2g
Flow rate: 1.65 MSCMD
Catastrophic rupture
VCE
At stability class 2F
bar, damage distance 293.51 m
At stability class 3D,
0.1 bar, distance-282.01 m
7.2.16
Natural and Manmade Calamities which can Lead to Emergency Scenerio
Goa exhibits low seismic activity (zone III) and has favourable location on the West Coast where
storms/cyclones are rare and mild. It is pertinent to note that even in Gujarat and Orissa 9
Paradeep), in spite of occurrence of major earthquakes as well as super-cyclones, Ammonia
storage tanks were unaffected and intact.
Incidents having off-site implications can be caused by:


manmade causes like air raids or crashing of aircraft
sabotage
A major emergency can originate from one or a combination of the following events:

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
Slow isolated fires
Fast spreading fires
Explosions
Bursting of pipelines/high pressure vessels
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Other Incidents
Other incidents, which can also result in a off-site emergency are:
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Agitation/forced entry by external group of people/vandalism
Bomb explosion
Effects of Stress & Strain cause during Normal Operation
In any industry during the plant operations, deviation from the normal condition is likely to occur
sometimes. These deviations may result in to certain stress and strain either in the equipment or
to controls. The stress and the strain generated so are nothing but the accumulation of the
chemicals/mechanical or electrical energy or a combination of these. This energy if not handled
properly may result in to the occurrence of hazard.
The stress and strain can be caused by corrosion & erosion, vibration and hammering.
Corrosion & Erosion
Ammonia, carbon dioxide, urea carbamate, acids etc. are corrosive in nature and can cause
corrosion to the equipment, vessels, piping’s etc.. Engineering controls have been taken in design
and operation to minimize or nullify the corrosion. For external protection, special paints are used.
Along with the engineering control regular monitoring are done to ascertain the health. The
techniques used are:
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External checks if vessels, equipment, piping’s;
Regular monitoring by operations & service dept.;
Non destructive testing methods by our Inspection dept.;
Corrosion coupons are also used in cooling water lines to know the healthiness of heat
exchangers and pipelines;
Residual life assessment.
Vibration
Vibration is another phenomenon which can cause stress and strain during the normal operations
and may cause damage. Some of the reasons can be imbalance of rotating components, defective
support system etc. For critical machinery online vibration monitoring system with alarm and trip
systems have been installed from design stage. The indications are available in control room for
operator guidance. In addition inspection dept conduct regular monitoring and keep history; all
these data are utilized for analysis to know health and take appropriate actions in time to avoid
damages.
Hammering
Hammering is another phenomenon which can cause stress and strain on the structure and
pipeline. This can dislocate the pipes from it’s place and lines get damaged from different
locations. Hammering can be caused due to accumulation of condensate in lines. Adequate
precautions are like steam traps, condensate removal system, vent and drains are provided to
minimize this effect.
Fire and explosion inside the plant and effect if any of fire and explosion outside
Fire and explosions inside the plant can be caused in the systems associated with Natural gas,
process gases in vessels. There may not be any direct effect of fire and explosion outside.
We have adequate in built safety features, monitoring and fire fighting facilities.
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7.2.17
CH-7: ADDITIONAL STUDIES
Details regarding Warning, Alarm, Safety & Security Systems
Warning, Alarm, Safety & Security System
An audible emergency siren system is provided which can be operated from two locations viz.
from Ammonia Plant and from Fire Station/Emergency Control Centre.
There are 4 sirens located in the entire factory so that the siren is audible as follows:




Above Ammonia Control room
Roof of DG building
Above WTP control room
Above NPK truck loading in Bagging plant
In addition to above “Off-site Siren” is also provided on the DG building which can be sounded
from Emergency Control Centre.
In addition buzzers have been provided in NPK-A, NPK-B and Bagging Control rooms.
The sirens will operate as below:
Onsite Emergency Siren
: Wailing sound for two minutes (4 seconds “on” & 2.5 seconds “off”)
Off-site siren
: Wailing sound for 2.45 minutes (2.5 seconds “on” and 1 second “off”)
All Clear Siren
Testing
: A continuous sound for a period of two minutes
: All sirens /buzzers are tested on 1st Monday of every month at 10:30 a.m.
from Ammonia Plant as well as from Emergency Control Centre
Safety System
ZACL has a good safety management system and a Fire & Safety Dept with qualified and
dedicated Safety Professionals. Necessary studies like HAZOP, QRA, EIA have been carried out
through reputed organizations like NEERI, EIL. The safety has been taken right from the design
stage. Any changes in the process/modifications are done under Plant Modification procedure
which involves HAZOP, Safety Assessment from Technical and Fire & Safety Dept. All the plants
have well established documented emergency shutdown procedures, safety relief system, early
warning and alarm system, round the clock monitoring of operations, uninterrupted power supply
etc.
All the jobs within and ZACL campus are carried out under a well documented Work Permit and
lock out tag out system. All the personnel including the contract workers have been provided with
PPE’s and action taken against the defaulters. 3 Tier Safety Committees are constituted involving
shop floor employees and meeting are conducted regularly. Safe Operations Committee headed by
MD are held once in 3 months.
For the involvement of contractor’s workers and also safe transportation of raw materials, separate
committees are constituted and action plan is drawn for implementation.
We have a system of reporting Make to Good condition/Near miss/incident/accident. The accidents
are investigated, analyzed and recommendations are implemented. All the accidents are reviewed
by Sr. Management.
The employees as well as the contract staff undergo fire & Safety training programs through
internal as well as through external faculties. Safety promotional activities are conducted to
motivate the staff.
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Specialized community awareness programmes are conducted on regular basis in association with
District Administration and Inspectorate of Factories & Boilers, Govt. of Goa. Leaflets on Dos’ and
Don’ts of Ammonia and what to do in case of emergency distributed among the community.
Periodic internal as well as external audits are conducted and review of the same is done for
implementation.
Security System
ZACL factory & other ZACL estate area in Goa, including the ZACL colonies in segregated pockets
are spread safeguarded by of 80 security personnel. Security is provided at all vulnerable points
throughout the complex all round the clock. The main body of security personnel are in 3
categories i.e. guards, head guards & security inspectors. The entry and exit at all gates are
verified by the security and then only allowed. Cameras are provided at the main gate and railway
siding which are monitored by Security Head. Metal detectors are provided at the main gate and
the DAP gate. All the contract staff are physically checked at the entry and exit. The entry of the
employees and regular contract workers is recorded at the entry and exit points. The security has
one four wheeler and two wheelers for carrying out the security job.
Alarm and hazard control plan in line with Disaster Control and hazard control planning, ensuring
the necessary technical and organizational precaution.
Technical Support Services
S. No.
Services
1
Toyo Engineering Corporation. Japan
2
Toyo Engineering (India) Ltd., Mumbai
3
Projects Development India Ltd., Sindri
4
Engineers India Ltd, New Delhi
5
National Environmental Engineering Research Institute, Nagpur
6
KLG-TNO, New Delhi
7
Confederation of Indian Industry
8
Tata Consultant Engineers, Mumbai
9
KBR, U.S.A.
10
Thermax
11
UHDE India Ltd.
12
BHPV, Vishakapatnam
13
LIQUE, France
14
Hindustan Dorr Oliver
15
INCRO, Spain
16
BHEL, Tiruchapally
17
TROJKA, Poland
Measuring instruments and control units and servicing of such equipment
Leak detectors have been installed in different plants depending upon the storage and handling of
the hazardous chemical. The types of detectors and their location depends upon probability of the
leak and it’s effect. Most of the detectors are connected to the plant control rooms. Manual Call
point alarms are available at Fire Station. All the detectors are calibrated periodically and checked
for working regularly.
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The list of detectors with their type, location and nos. is as below:
S.
No.
Type
Location
Qty.
Ammonia Plant
1
NG leak detector -%LEL
Reformer, combustion chamber
25
2
Ammonia leak detectors -PPM
Storage and pump area
15
3
Ammonia leak detectors -PPM
Ammonia Unloading
3
4
Smoke detectors
compressor house
4
1
Ammonia leak detectors -PPM
Urea Plant - storage and pump area
4
Urea Pant
Utilities
1
Ammonia leak detectors -PPM
Water Treatment Plant
1
2
NG leak detector -%LEL
Power Plant -burner area
5
3
Chlorine leak detector - PPM
Pre- treatment in WTP
1
4
Smoke detectors
DG room
2
1
Smoke detectors
Product Handling Plant
Bag storage area
4
Incident control room will be established as soon as emergency occurs. The control room of the
affected plant will be the incident control room. Site Coordinator will send / receive communication
from this control room to persons concerned.
Telephone nos. of the incident control room shall be immediately conveyed to the Emergency
Control Centre or Alternate Control Centre.
7.2.18
Precautions in designing of the foundations and load bearing parts of the
building
Safety in design of foundations
Foundation of a structure is like the roots of a tree without which the tree cannot stand. Thus, the
Design of Foundation of and Civil Engineering Structure, may it be a simple Residence Building or
a Sky Scraper, is of paramount importance.
Foundations can be broadly classified as Shallow Foundations and Deep Foundations, depending
upon the difference of level between the ground surface and the base of the foundation.
A specific type of Foundation is adopted after undertaking extensive Geo Technical studies to
determine the type of soil and to ascertain the depth at which the hard strata is available.
While designing Foundations the following point should be borne in mind:


It is necessary that a Foundation is so designed that if at all a settlement should occur, then it
will be uniform ie the settlement for all the footings will be more or less the same.
All structures in Zuari Agro Chemicals Ltd. have been designed considering a Safe Bearing
Capacity of Soil as 20 tonnes per sq.mts. The foundations of structures in Zuari are resting on
hard lateritic strata.
Safety in design of load bearing parts
Load Bearing structures play a vital role in effective transfer of load to the foundations. As such, it
is of vital importance that they have to be designed properly after working out the loads that will
be transmitted to the various load bearing components of a structure. Correct Engineering
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Practices as laid down in the National Building Codes have to be followed at the time of casting /
erection of the load bearing structures.
Some of the most common Load Bearing Structures of any Engineering structures are Beams,
Columns, Slabs, Shear Walls etc.
For enhancing the stability of load bearing Masonry walls, RCC bands are provided at the Plinth
level and below the roof slab level.
It is of paramount importance that a stability check of such load bearing structures is undertaken,
at least once in 5 years, to ascertain the health of the same. In Zuari Agro Chemicals Ltd., the
load bearing components of an RCC or Steel structure are tested once in every 5 years by
appointing an approved residual life assessment agency who carries out the inspection work by
using Non Destructive techniques like Rebound Hammer Testing, Visual Inspection etc.
Continuous surveillance of operations
Continuous surveillance of Operation of the process is done through the following online systems:





Continuous monitoring of the necessary process parameters from the centrally located control
room;
Continuous automatic process control from automatic Coordinators;
Continuous monitoring of the process analysis through process analyzers;
Emergency shutdown systems;
Quality control Laboratory.
This system enables the operators who work on shifts to be in complete command of the process
status.
Continuous Monitoring
This is being done by sensing the process parameters through dedicated transmitters, which in
turn send signals to the monitors in the control room. These monitors consist of analog and digital
indicators, recorders, and graphic displays in some plants on DCS (Distributed Control System) or
Data acquisition system, which in essence are Programmable Computers. The signals also are
provided for annunciators, which alarm the operator to the alert and danger levels of the
respective process parameters so that suitable action may be taken to restore back the normal
conditions. The motors and other drives have continuous indications on the panel showing their
status of operation. In some areas/plants there are data acquisition systems, which use computer
displays, showing the active process graphics, trending, and alarm summary displays, all on real
time basis. Also it gives historical trending and archives, which give the data storage for days
together. These computers are capable of giving the shift report and daily reports as desired by
the operational requirement. A large array of data helps in obtaining plant efficiencies, loading
capabilities, desired capacity levels, optimization and other flexibility as required for higher order
data management.
Continuous Automatic Process Control
Process Coordinators with artificial intelligence of pneumatic and electronic origin are used to
automatically control the process parameters under closed loop basis. Accordingly the operator
sets desired set point where the process parameters should be resident. The Coordinator
automatically controls the process parameters to keep the measurements coinciding with the set
point set by the operator. Momentary deviations between set point and measurement valves are
immediately controlled from the control algorithms processed automatically by Coordinators. The
Coordinator commands the actuating element mostly control valve which actuate the process to
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maintain it at desired set point. The option of automatic and manual switch is provided in the
control station located in the control room. This control station serves as the man-machine
interface to the operator to decide if the particular parameter needs to be controlled either in
manual or in auto. While in auto the Coordinator takes charge of the parameter to control it
automatically and the manual mode serves the operator to control himself manually should he
desire to do so.
Process Analysis
The online process analysis is done through these analyzers who determine the chemical
compositions of the process. This helps in the basic processing of the intermediary and end
product and indirectly the efficiencies. The sensors for these analysers are strategically located at
different sections of the plant to enable the operator to analyse the process conditions. Alarms in
the monitoring of these analysers alert the operator of its threshold and danger levels so that any
limitations can be maneuvered to correct the process quality.
Emergency Shutdown Systems
To automatically determine the safety of the process equipment and manpower, the automatic
emergency shutdown system has been provided for each plant. The shutdown and safety devices
which consist of trip relays, solenoid valves, relief valves, safety valves, control valves,
programmable logic Coordinator will set and integrate to trip the plant/shutdown automatically or
manually on request, should there be any override of the process parameters, reaching to danger
levels. Every time before starting the plant, this shutdown trip system is tested by simulation to
check the health of the trip device, its response time, set values and its authenticity. The
emergency shutdown system has alarming functions to diagnose the cause of the trip and whether
a safe shutdown has taken place. The components of this system is most of the time duplicated to
provide redundancy and enhanced reliability so that it serves as a watchdog to guard the plant
from abnormal process parameter levels.
Quality Control Laboratory
The Laboratory is well equipped to provide detailed analysis of all the compositions as required by
the process. Its manpower works in rotational shifts round the clock and has a schedule of various
analysis which are to be carried out, offline on periodic time basis. In some plants, there are
facilities of automatic analyzer to analyse the composition of end product of some of the products
manufactured by the Company. Most of the instruments are of the latest microprocessor based
origin having very high fidelity and accuracy. Some of the instruments are gas chromatographs,
spectrophotometers, digital titrators, electronic balances, pH and conductivity monitors etc. Other
forms of analysis through reagents, titrations and dedicated reactions are carried out to determine
and counter-check various compositions. The complete data is logged through computers and
store in its database. The Laboratory operating personnel have fixed scheduled to give the process
data analysis of the respective plants at predetermined times to the plant operators.
Maintenance & Repair Work Procedures according to the Generally Recognised Rules
of Good Engineering Practices
The maintenance work in the continuous chemical process plants at ZACL may be classified under
disciplines namely Civil, Mechanical, Electrical and Instrumentation.
The maintenance work may be categorised in all the above disciplines as follows:


Day to day minor repair work in the running plants;
Preventive maintenance during the running of the plants;
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Preventive Maintenance during plant shutdown;
Plant shutdown repairs;
Replacements of the equipment/machinery due to ageing and obsolescence;
Technical inspection of pipelines, vessels, rotating machines, based on the guidelines of the
standard practice;
Predictive condition based maintenance of various machinery’s;
Redesign and modifications for optimizations and prevention of recurring failures and
downtime;
Procurement of spares and update parts / machinery /equipment / instruments.
Monitoring of all these above activities is being followed through registrations in the computerized
maintenance management system (IMPACT). Also history of all maintenance work carried out,
which was previously maintained in history cards has been updated into IMPACT. The latest
methodology of computerized maintenance work is being used. This computerization helps to
update the data management of all the maintenance work and provides a ready reference guide to
plan the work in advance in an enhanced structured manner. Monitoring of individual equipment
as regards its maintenance is now being trended/recorded to facilitate the logistics towards
determining the health of the equipment.
Maintenance work followed under good engineering practices.
Day to Day Minor Repair Work in the Running Plants
This work is initiated by the operations on daily basis through the formats of work request and
safety permits. Proper isolations of the work area is being done in the presence of operation and
maintenance staff and once the isolations are confirmed by checking through various instruments
such as explosive meters, oxygen meters, CO/CO2/H2 meters etc. Work is being carried out under
the direct supervision of maintenance engineers. Once the work is completed and the units are
tested and found satisfactory to be taken in line/commission, through the same work permit,
maintenance engineers hand over the jobs done to the operation supervisors, who in turn put
back the units in operation.
Preventive Maintenance during the Running of the Plants
Preventive maintenance schedules in the standby equipment and in the equipment/ units/
instruments wherever possible is being carried out on time basis. This also includes LLF methods
(Look-Listen-Feel method) wherein operation staff / maintenance engineers/technicians make
regular rounds to check the leakage, the abnormality of sounds, the heat dissipations, optimum
lubrication oil levels and its make up, external vibrations. They thus obtain the first hand
knowledge of the performance of the plant equipment/instruments/machinery.
Preventive Maintenance during Plant Shutdown
During the shutdown of the plants or annual turnaround, checking the alignment of machinery,
testing and simulation of instrumentation, electrical equipment, periodic replacements of units
such as bearings, bushes etc., internal cleaning and servicing of equipment/machinery,
replacements of worn-out parts well in advance before a breakdown occurs, testing of foundations
of equipment and machines, calibration of instruments, emergency trip devices, checking of the
safety devices such as safety valves, relief valves etc. are the areas which are planned as a
shutdown activity during the plant shutdown. All the moving and rotating parts are being
lubricated, fresh lot of lubrication oils are replenished in order to render a trouble free service till
the next annual turnaround.
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Plant Shutdown Repairs
The repair work based on the breakdowns or inspections done during the running condition of the
plants are being carried out during the shutdown in all the disciplines including Civil. Replacement
and repair of refractory of furnaces, repairs of vessels and pipelines, repairs of control valves,
instruments, repair of rotating machines, safety equipment, etc. are few examples where the work
is taken up during shutdowns. The isolation procedure of shutdown jobs during shutdown is the
same as that of the isolation procedure during running of the plant. Job permits are being
renewed in every shift and maintenance as well as operating personnel does monitoring.
Replacements of the equipment/machinery due to ageing and obsolescence
To enable the long term planning so as to keep the plant running for a long time, safeguards
against ageing and obsolescence is of utmost important and this is mostly being planned for
execution during plant shutdowns/ turnarounds. At times, detail engineering to redesign these
modifications is required to incorporate suitable alternatives due to the non-availability of spares,
so as the equipment/machinery is serviceable without sacrificing safety and good engineering
practices.
Technical inspection of pipelines, vessels, rotating machines, based on the guidelines
of standard practice
A separate section is in charge to check/inspect the quality of welding, the vessel internal
leakage’s, equipment internal deterioration, and to monitor the long-term health prospects of the
equipment. All the fresh weld joints are tested/ X-rayed as per the standard procedures.
Recommendations for the type of materials and a constant pursuit to incorporate better materials
are supervised by this section. This work is being carried during the breakdowns or annual
turnaround, or during the running of the plants. Internal testing of the exchangers or peel-off of
vessel linings, or internal material erosions are another areas where this section plans and advises
to other sections for the repair activities if necessary.
Predictive maintenance of various machinery
All rotating machines of different types are undergoing online and off-line predictive monitoring to
determine its performance on continuous basis. This monitoring includes vibration, axial thrust,
eccentricity analysis, check of bearings through shock pulse methods, orbit analysis to determine
the alignment of shafts are some of the areas where the dedicated team under equipment section
is continuously monitoring on off-line basis. All the daily readings are tabulated and computerised
and various trends are drawn to manage the data and provide signals, which can alert the
maintenance and the operation. The on-line predictive monitoring consists of sensors which
continuously monitor the parameters such as vibration, axial thrust displacements etc. and provide
a direct on-line recording. This helps in triggering signals to alert the plant operators and trip the
plants in case of emergencies.
Redesign and Modification for Optimization and Prevention of Recurring Failures and
Downtime
These are the backup services for maintenance which give a continuous feed backs of the latest
developments so that it can be incorporated in the existing system to keep the equipment/
machinery updated with the latest technology. It also helps to eliminate the long-term
shortcomings in the older designs and look for upgrading the plant efficiencies and energy
savings. Its work is of project nature, mostly to be done or hooked up during shutdowns. The job
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CH-7: ADDITIONAL STUDIES
involves design, detail engineering, procurement, erection/installation and commissioning and is
undertaken by Maintenance Department.
Procurement of spares and updated parts /machinery /equipment /instruments
Planning for the complete maintenance work, its spares, replacements, and redesigns wherever
necessary is a continuous activity, which is being planned in anticipation to the actual maintenance
needs for the plant use.
7.2.19
Emergency Control Procedures
Evacuation Procedure
In case of any emergency, evacuation of the personnel is very essential. We have identified 12
Assembly Points where the personnel have to assemble. All these Assembly Points are in charge of
persons who will be responsible for doing Head count and shifting them to a safer place.
The Welfare Coordinator along with Security coordinator shall be the Key Persons who are in
charge of evacuation. If required, they may take assistance from the other persons reporting to
ECC. For evacuation of the plant personnel, two routes are identified which shall be used
depending upon the wind direction.


Main Gate House
DAP gate (Materials Gate)
List of vehicles which will be made available for transporting people in case evacuation is required
is as follows:
Type of vehicle
No. of vehicles
Contact No
Buses
5
9850035599, 9765376438
Light motor vehicle
8
9921853500, 9762476107, 9823157833
The company owned cars and personal cars of the employees if required can also be used for
evacuation.
Medical Emergency Procedure
The affected persons will be provided first aid and then transported with available means of
transport to the Health Centre. Once the casualties arrive at Health Centre, Medical Coordinator
will examine and decide upon sending them to the pre-identified hospitals. It is the responsibility
of the Medical Coordinator to inform the Over-all in Charge about the condition of the injured.
Restoration of Normalcy
After confirmation from all the coordinator that the emergency is controlled and in consultation
with the Over-all in Charge, the Chief Coordinator will authorize to sound “ALL CLEAR”.




Once the “ALL CLEAR” is sounded, it is indication that the emergency is over;
All external agencies like District Collector, Inspectorate of Factories & Boilers, and Police will
be informed by the Overall in Charge regarding cessation of the emergency;
Overall in-charge informs to higher up about the end of emergency;
Each plant shall resume to the normal operation after assessing the situation and following
the laid down procedure of plant start-up.
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Training and Emergency Drills
Training
All the key persons, the coordinator of the response team and other required persons in the plant
are trained on their role during emergency. The following are the some of the areas where the
persons will be made aware of.







Safe handling of hazardous chemicals;
Procedure to be followed in reporting emergency;
Siren and manual call points;
Usage of fire extinguishers;
Use of different types of PPE’s;
First aid;
Evacuation procedure;
Emergency drills.
The following types of exercises and drills will be conducted.
Wet drills
:
Once in a month
Full-scale drill
:
January and December
Plan Review and Updating
The plan will be reviewed and updated.



The shortcoming observed during conduct of table top exercises/ mock drills.
Any change of process, handling of new hazardous chemicals.
Change in coordinator, their contact numbers.
The updating of the plan would be the responsibility of In-charge of Fire & Safety Dept. The
updated Plan would circulated to the concerned after the same is approved by Chief General
Manager-Operations/Chief Manufacturing Officer.
Controlled copies
Each controlled copy of the plan will be serially numbered and then issued to the concerned
person. The details of the same will be documented by in-charge of Fire & Safety. It will be the
responsibility of the concerned person to send back the old copy/pages to Fire & Safety Dept.
7.2.20
Details of Communication Facilities Available during Emergency
Method of Reporting and Declaration of Emergency
Any person noticing a fire, explosion or release of hazardous material should shout 'FIRE’ or ‘HELP’
and attempt to control the incident. He/she should dial 101/111 (Fire Station/ECC) or break the
nearest Manual Call Point, which automatically alerts the fire station, and its nearest location. The
telephone number 101/111 at the Fire Station/ECC is manned round the clock.


He should inform the shift-in-charge of the affected plant, giving the location of incident, brief
description of the emergency. The shift-in-charge should confirm by repeating the message
back to caller to proper communication;
Fires station will then press the bell to call Panel Operator from Weigh Bridge and Fire &
Security Inspector from main gate;
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Panel Operator will immediately contact the coordinators and the information will flow as per
the attached communication chart.
The Message must be Clear, Short and should Contain:






Identification of the speaker;
Brief Description of the incident;
Location incident;
Status and seriousness of the situation;
Actions taken;
Immediate assistance required.
Declaration of Emergency
Localized emergency
The emergency situation arising in any section of one particular area which is minor in nature can
be controlled within the affected section itself with the help of in-house resources available at site
and the fire department. such emergencies should be informed to the chief coordinator.
Such an emergency does not have the potential to cause serious injury or damage to
property/environment and the domino effect to the sections of the affected plant or near by
plants/areas.
Major emergency
The emergency which cannot be controlled locally and has the potential to develop into a major
emergency with a potential to cause serious injuries or damage to properly/environment within
the affected area or to the nearby areas should be considered as a major emergency needing
immediate action and this plan would need to be activated. Such emergency situations always
warrant mobilizing the necessary internal and external resources to handle the emergency and
mitigate it’s consequences.
Immediate Actions for Major Emergency







The senior most officer available at the site must immediately inform Chief Coordinator and
ECC about the escalation of emergency;
After receipt of the call, Chief Coordinator will rush to the incident site;
Chief Coordinator after assessing the situation, take appropriate action to control the situation
and if it is beyond his control, informs the Overall In-charge. Chief Coordinator will direct the
Fire & Safety Coordinator to initiate sounding of emergency siren who in turn will ensure
prompt/immediate action for sounding of siren;
Overall In-charge would get in touch with ECC;
The panel operator at ECC would inform GM-M, Health Centre, Main Gate House, CM-F&S,
DGM-M&S, CM-I&E;
Overall In-charge would then rush to ECC;
After assuming the position of Overall In-charge in ECC, he shall contact with other senior
members in the plant.
Procedure for Sounding the Emergency Siren
An emergency alarm switch is installed in the Emergency Control Centre (Fire Station) and also in
Ammonia Plant. The siren can be sounded with the actuation of an “Emergency Alarm Switch”.
Chief Coordinator will direct Fire & Safety Coordinator to initiate sounding of the emergency siren
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CH-7: ADDITIONAL STUDIES
from the ECC. The siren can also be sounded by the shift-in-charge only in case of an extreme
emergency.
The siren will be operated in the following modes.
Onsite Emergency Siren
A wailing sound for two minutes (4 seconds “on” & 2.5 seconds “off”)
Off-site siren
A wailing sound for 2.45 minutes (2.5 seconds “on” and 1 second “off”)
All Clear Siren
A continuous sound for a period of two minutes
Action by emergency staff
Fire pump operation
We have a good net work of fire hydrant system all throughout the plant. The water pressure is
continuously maintained at 7.5 kg/cm2. Any drop in water pressure, the fire pumps will start
automatically.
Security



On hearing emergency siren or on information, the fire fighting team will report to the
incident site;
Control and monitor the traffic movement;
All hot jobs inside the plant to be stopped.
Trained Fire fighting staff
All the trained fire fighting staff from the non plant areas will report to the Emergency Control
Centre and assist the emergency team, if required.
First Aiders
The certified first aiders belonging to non-plant areas have to proceed to the Health Centre and
assist the medical team, if required.
Other personnel
All the personnel not directly involved in emergency operations should proceed to the designated
Assembly Points, if the same is ordered by the Overall in-charge.
Sequence of Actions after Declaration of Emergency





After declaration of emergency, overall in-charge instructs communication Coordinator to
inform nearby hospitals, Police Station and Mutual Aid Members. Chief Manager-Fire &
Safety/Manager will assist in these operations;
Maintenance team reports to the incident site, if needed;
Overall In-charge will keep contact with Chief Coordinator;
The other plan in-charges occupy their respective plant and follow the instructions from Chief
Coordinator/Overall in Charge;
Overall In-charge in consultation with the Chief Coordinator and other key personnel decides
whether to shutdown the plant.
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CH-7: ADDITIONAL STUDIES
Other Guidelines
Fire personnel
The fire personnel represent in ECC/Fire Station or other designated person will act as ECC
operator.
ECC operator




To receive all incoming calls;
To inform Health Centre, Chief Manager-Fire & Safety, Main gate house;
To keep record of all incoming calls;
To assist the Communication Coordinator/Overall In-charge in communications.
Communication of Emergency
The emergency will be communicated to all by sounding of Emergency Siren. The Chief
coordinator briefs the Overall In-charge about the status, likelihood to affect other plants. The
mode of communication will be public address system, walkie talkie sets, internal /external
telephones or messengers. The various channels of communication are as below:
External communication
1. If, required key personnel can be contacted by external telephones.
2. Communication to nearby communities
Overall In-charge through GM-HR establishes telephonic contact with the identified key
persons in the neighbouring communities.
3. Communication to local authorities
Overall In-charge will contact local authorities like District Collector, Dy. Collector, Police, Fire
Station, Chief Inspector of Factories & Boilers. through the Communication coordinator.
4. Designated person for interaction with media
Sr. Manager-CSR & PR would be the Company’s authorized spokesperson for interacting with
media (TV channels, newspaper, etc)
5. Procedure for notifying families of the injured person
The responsibility of communicating to the families would be of GM-HR.
6. Centralised reporting office
ECC would be the Centralised Reporting office during the emergency.
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CH-7: ADDITIONAL STUDIES
Details of Fire Fighting & Other Facilities
The fire protection system at ZACL consists of the following:







Fire water hydrants, water foam monitors with fire pump system;
Long range trolley mounted water foam monitor;
Portable fire extinguishers;
Fire vehicles (2 nos.) – Foam Tender & Water Mist Tender;
Emergency Response Vehicle;
Hydrocarbon/smoke detectors with alarm;
Manual call point system (break glass type).
List of firefighting Equipment & Others
S. No.
Equipment
Quantity
1
2
Fire hydrant
Single hydrant
45 nos.
Double hydrants
72 nos.
Fire escape risers
54 nos.
Water/foam capacity for fire fighting
9687 M3
Raw Water Pond
Water monitors tank farm area
6 nos.
Foam compound in foam tank
2800 lts.
Fire pumps
3
Diesel engine driven pump
: 2 no’s, 410 m3/hr, head 88m
Electrically driven pump
: 1 no., 410 m3/hr, head 88m
Jockey Electrically driven pump
: 2 no’s, 50 m3/hr, head 88m
Smoke /Heat detectors
4
5
Ammonia Compressor house
8 no’s
DG Room
2 no’s
Product handling plant
8 no’s
Library
04 no’s
Safety Training Centre
04 no’s
Stores
11 no’s
Works Office
25 no’s
Health Centre
11 no’s
Manual Call points
17 no’s
6
Hoses
7.5 m length
2
15 m length
7
103
Fire extinguishers
Dry Chemical powder 5 Kg
20
Dry Chemical powder 10 Kg
264
Dry Chemical powder 25 Kg
9
Dry Chemical powder 50 Kg
5
Foam type 9 liters
55
Carbon dioxide 2 Kg capacity
5
Carbon dioxide 4.5 Kg capacity
61
Carbon dioxide 9 Kg
23
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Equipment
S. No.
8
Quantity
Foam tender
Water tender
1 no
Water tank capacity
4000 lts.
Foam capacity
1000 lts.
Pump capacity
3000 lpm @ 7 kg/cm2
DCP
75 Kg (2 no’s)
Water Mist Tender
1 no.
Water tank capacity
2000 liters.
DCP vessel capacity
500 Kg.
Pump capacity
150 lpm @ 100 kg/cm2
Emergency Rescue vehicle
1 no.
9
10
CH-7: ADDITIONAL STUDIES
Equipped with various types of items
11
Trailer mounted foam monitor
1 no.
Capacity
4500 lpm
Self Contained Breathing Apparatus
44 nos.
13
Chemical suits
14 nos.
14
Dewatering pump
1 no.
Capacity
700 lpm
15
Fire proximity suits
2 nos.
16
Compressor for filling breathing air
1 no.
12
List of other Safety Equipment
S. No.
Equipment
Quantity
1
Trolley mounted long range breathing apparatus
3 nos.
2
Self contained breathing apparatus
nos.
45 minutes duration
24
-
30 minutes duration
20
17
3
4
Spare cylinder
Sets
Air line respirator
8 nos.
Canister gas masks
Ammonia
13 no’s
Urea
9 no’s
Utilities
10 no’s
NPK-A
8 no’s
NPK-B
7 no’s
RMH
4 no’s
DAP Gate house
5 no’s
Laboratory
2 no’s
Detecting Instruments
Plant
Measuring Components
Ammonia
LEL, O2, CO
Urea
NH3
Urea
O2
NPK-A
NH3
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Plant
Measuring Components
NPK-B
LEL, O2
Power Plant
LEL, O2
Laboratory
LEL, O2, CO
Fire Station
LEL, O2
Wind direction indicators
Wind directors have been provided at various locations which are as under:
Old Horton sphere
:
1 no.
New Horton sphere
:
1 no.
Chlorine handling area
:
1 no.
In front of Health Centre
:
1 no.
CO2 absorber
:
1 no.
RMH office
:
1 no.
Details of First AID & Hospital Services Available & It’s Adequacy
Medical Arrangements
On receipt of emergency call ambulance will be immediately sent to the emergency site. First
aiders of the affected plant shall assist the emergency team at the site immediately and
subsequently the medical team at health centre. First aiders of non affected plant may be called to
assist the medical team depending on the number of the casualties. List of trained first aiders is
appended.
Medical officer (in his absence male nurse on duty) will act as medical coordinator. He will guide
the first aiders and the medical team. The Doctor will coordinate with chief coordinator. After
giving the first aid the casualty would be referred to higher medical care centre or detained at
health centre depending on the nature and severity of the trauma.
Health Centre
Occupational health centre situated inside the factory premises operates round the clock with
following facilities:
S. No.
Manpower
Number
1
Resident Doctor
1
2
Visiting Doctor
1 (Retainer)
3
Nursing Staff
4
4
First Aiders
50
S. No.
Equipment
Number
1
Ambulance
01
2
Beds
04
3
Oxygen Cylinders
02+02
4
Oxygenators
02
5
Stretchers
04
6
ECG
01
7
Glucometer
01
8
Nebulizer
01
9
Casualty Tables
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CH-7: ADDITIONAL STUDIES
Ambulance
There is an ambulance stationed at health centre round the clock. Whenever there is an
emergency ambulance is sent to the site and with the help of first aiders/rescuers the casualty is
brought to the health centre. If the person is serious he is referred to hospitals after giving first
aid for further management.
List of Emergency Medicines at Health Centre
S.
No.
Emergency medicine
S.
No.
Emergency medicine
S.
No.
Emergency medicine
1
Inj Atropine.
18
I V Fluids.
35
Tab Vertin.
2
Inj Adrenaline.
19
Inj Tramadol.
36
Tab Valium 2.
3
Inj Rabipur.
20
Inj Calmpose.
37
Tab Trika 0.25.
4
Inj Tetanus Toxoid.
21
Inj Eptoin.
38
Tab Digine.
5
Inj Avil.
22
Inj Dolokind Aqua.
39
Tab Calpol/Crocin.
6
Inj Dexona.
23
Tab Sorbitrate.
40
Tab Lostat.
7
Inj Voveran.
24
Tab Avil.
41
Tab Stamlo.
8
Inj Reglan.
25
Tab Combiflam.
42
Tab Meftal Spas.
9
Inj Phenargan.
26
Tab Diclogesic.
43
Tab Mobizox.
10
Inj Gentamycin.
27
Tab Lasix.
44
Tab Bidanzen Forte.
11
Inj Stemitil.
28
Tab Atenolol
45
Tab Flexon Mr.
12
Inj Lasix.
29
Tab Enam.
46
Eye Wash Cups.
13
Inj Deriphyline.
30
Tab Telmisat.
47
Silverex Cream
14
Inj Betropose.
31
Tab Ecosprin.
48
Ryele’s Tube.
15
Inj Ranitidine.
32
Tab Clopitab.
49
Foley’s Catheter.
16
Inj Cyclopam.
33
Tab Depin.
50
Eye/Ear Drops
17
Inj 25% Dextrose
34
Tab Cardace
Facilities Available





Consultation;
Emergency handling;
Suturing facility;
Medical examination;
Transportation to referral centers.
Multiple Casualties Handling
In the event of a disaster involving multiple casualties, help of nearby hospitals/ doctors and their
paramedical staff would be available. The Company doctor shall arrange such help from the
outside whenever required. The list of such hospitals is given below:
List of Hospitals –Govt & Private
S. No.
Name & location
Type
Beds
Phone no.
1
Primary Health Centre, Cansaulim
Govt.
12
2754036
2
Primary Health Centre, Cortalim
Govt.
-
2550274
3
Cottage Hospital, Chicalim
Govt.
60
2540864
4
SMRC, Chicalim
Private
100
6691919
5
MPT Hospital,
Semi Govt.
100
2594931
6
INHS, Jeevanti, Vasco
Govt.
79
2501233, 2501022
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Name & location
Type
Beds
Phone no.
7
Talaulikar Hospital, Vasco
Private
22
2513456
8
Dr. Kamat Nursing Home, Vasco
Private
12
2512354
9
Dr. Pai Hospital, Vasco
Private
25
2513641, 2511899
10
Sanjeevani Hospital, Baina
Private
39
2510024
11
Raj Tara Hospital, Vasco
Private
8
2514883
12
Dr. Mesquita Maternity & Eye Hospital, Vasco
Private
14
2513696
11
Vasco Clinic, Vasco
Private
11
2513164
S. No.
12
Goa Medical College
Govt.
955
2458700
13
Dr. Parulekar Nursing Home, Baina
Private
25
2513672
List of Employees Trained in First AID
S. No.
EPR
Section
Section
Tel. no.
1
2339
Sarvesh Karapurkar
Utilities Plant
2690
2
2420
Gauresh Arondekar
Laboratory
2653
3
2421
Rupesh Kotharkar
Laboratory
2653
4
2423
Seby Barreto
Utilities
2690
5
2426
Nitesh Nadkarni
NPK-B maintenance
2332
6
2447
Hanumant Bykod
Ammonia Plant
2670
7
2448
Suraj Chodankar
Ammonia Plant
2670
8
2449
Savel Selveira
Urea Plant
2661
9
2442
Manesh Naik
NPK-B Plant
2660
10
2454
Gladwin Gonsalves
Ammonia Plant
2670
11
2456
Samarth Tendulkar
NPK-A Plant
2685
12
2434
Amresh Sawal
Fire & Safety
2622
13
2467
Preetesh Prabhu
Urea Plant
2661
14
2463
Rahul Gurav
NPK-B plant
2660
15
2464
Arjun Kattimani
Utilities Plant
2690
16
2466
Clive Lobo
Laboratory
2653
17
2465
Aditya Kalangutkar
Utilities
2690
18
2457
Satish Vaghmare
NPK-A Plant
2685
19
80001
Armildo Dias
Utilities Plant
2690
20
80003
Utkarsh U Laad
Ammonia Plant
2670
21
80004
Roland F.Pereira
Ammonia Plant
2670
22
80005
Dattaram M Sawant
Ammonia Plant
2670
23
80006
Bhaskar M Naik
Ammonia Plant
2670
24
80007
Akshay Naik
Urea Plant
2661
25
80008
Manu Krishnan
Ammonia Plant
2670
26
80009
Jayant G Kopardekar
Utilities Plant
2690
27
80002
Minanath Mandrekar
Laboratory
2653
28
80012
Audhut Parker
NPK-A
2686
29
2495
Sarvesh G. Naik
Instruments
2547
30
2504
Siddhesh Mhalsekar
Civil
2618
31
2515
Avinash Bhargav
Technical Services
2591
32
2514
Kishor J.
Urea Plant
2661
33
2516
Santhosha
Ammonia Plant
2670
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S. No.
EPR
34
35
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CH-7: ADDITIONAL STUDIES
Section
Section
Tel. no.
2517
Nishanth Gowda R.S.
Ammonia Plant
2670
2510
Reuben Anthony Torcato
Inspection
2638
36
2508
L. Ramesh Babu
Ammonia Plant
2670
37
2513
Kanakava Roy
Instruments
2547
List of Employees Trained in Fire Fighting
S. No.
EPR
Name
Plant /Section
Tel. No.
1
2036
Prashant Salvi
Utilities
2690
2
2351
Sankalp Kulkarni
Technical Services
2591
3
2448
Suraj Chodankar
Ammonia
2670
4
2508
Ramesh Babu
Ammonia
2570
5
80008
Manu Krishnan
Ammonia
2670
6
2083
Akash Valke
Urea
2661
7
80007
Akshay Lobhanand Naik
Urea
2661
8
2457
Satish Vaghmare
NPK-A
2685
9
2422
Manesh Govind Naik
Utilities
2660
10
2086
Vivek Mayenkar
Product Handling
2586
11
2068
C.L.A. Fernandes
Mechanical
2332
12
2510
Reuben Anthony Torcato
Inspection
2638
13
2378
Ramesh Meti
Mechanical
2452
14
2345
Saurabh Bandodker
Electrical
2584
15
1566
Savio Barreto
Electrical
2451
16
2340
Jayant Nirmalker
Instruments
2547
17
2280
Chandresh Chari
Mechanical
2480
18
2386
Aditya Kuttikar
Laboratory
2653
19
2277
Anup Madkaikar
Inspection
2638
7.3
OCCUPATIONAL HEALTH
Details of workers health of ZACL is given as below:
KADAM ENVIRONMENTAL CONSULTANTS | SEPTEMBER 2016
235
M/S. ZUARI AGRO CHEMICALS LTD.
EIA & EMP FOR CUSTOMIZED NPK FERTILIZERS UNIT, GT, HRSG,
AAST & UREA GRANULATION UNIT
CH-7: ADDITIONAL STUDIES
Health Status of Workers, ZACL
KADAM ENVIRONMENTAL CONSULTANTS | SEPTEMBER 2016
236
M/S. ZUARI AGRO CHEMICALS LTD.
EIA & EMP FOR CUSTOMIZED NPK FERTILIZERS UNIT, GT, HRSG,
AAST & UREA GRANULATION UNIT
CH-7: ADDITIONAL STUDIES
ECG Report
KADAM ENVIRONMENTAL CONSULTANTS | SEPTEMBER 2016
237
M/S. ZUARI AGRO CHEMICALS LTD.
KADAM ENVIRONMENTAL CONSULTANTS | SEPTEMBER 2016
EIA & EMP FOR CUSTOMIZED NPK FERTILIZERS UNIT, GT, HRSG,
AAST & UREA GRANULATION UNIT
CH-7: ADDITIONAL STUDIES
238
M/S. ZUARI AGRO CHEMICALS LTD.
EIA & EMP FOR CUSTOMIZED NPK
FERTILIZERS UNIT, GT, HRSG, AAST
& UREA GRANULATION UNIT
CH-7: ADDITIONAL STUDIES
Audiometry Report
KADAM ENVIRONMENTAL CONSULTANTS | SEPTEMBER 2016
239
M/S. ZUARI AGRO CHEMICALS LTD.
EIA & EMP FOR CUSTOMIZED NPK
FERTILIZERS UNIT, GT, HRSG, AAST
& UREA GRANULATION UNIT
CH-7: ADDITIONAL STUDIES
Health Check-up Report
KADAM ENVIRONMENTAL CONSULTANTS | SEPTEMBER 2016
240
M/S. ZUARI AGRO CHEMICALS LTD.
EIA & EMP FOR CUSTOMIZED NPK
FERTILIZERS UNIT, GT, HRSG, AAST
& UREA GRANULATION UNIT
CH-7: ADDITIONAL STUDIES
List of W/C & Urinals in Factory Premises
S.
No
LOCATION
GENTS
W/C
LADIES
W/C
URINALS
1
FIRE STATION
1
0
1
2
DOCUMENTATION/KNOWLEDGE CENTRE
1
1
0
3
WORKS OFFICE
3
1
2
4
WORKS CANTEEN
1
1
2
5
MAIN GATE
1
0
1
6
HEALTH CENTRE
1
0
0
7
STORES
2
0
2
8
MAINTENANCE WORKSHOP
2
0
2
KADAM ENVIRONMENTAL CONSULTANTS | SEPTEMBER 2016
241
M/S. ZUARI AGRO CHEMICALS LTD.
S.
No
EIA & EMP FOR CUSTOMIZED NPK
FERTILIZERS UNIT, GT, HRSG, AAST
& UREA GRANULATION UNIT
CH-7: ADDITIONAL STUDIES
LOCATION
GENTS
W/C
LADIES
W/C
URINALS
9
MAINTENANCE OFFICE
1
1
2
10
INSTRUMENT WORKSHOP
2
0
2
11
ELECTRICAL WORKSHOP
1
0
0
12
LABORATORY
2
1
0
13
WATER TREATMENT PLANT
2
0
0
14
LABOUR TOILET NEAR WTP
1
0
0
15
AMMONIA/UTY/UREA MAINT OFFICE
3
0
4
16
POWER PLANT CONTROL ROOM
2
0
1
17
DG CONTROL ROOM
1
0
1
18
DAP GATE SECURITY OFFICE
1
0
0
19
CONTRACTOR`S LABOUR TOILETS
2
2
1
20
AUTO WORKSHOP
1
0
3
21
NPK LABOUR TOILET
1
0
2
22
NPK -A CHANGE ROOM
2
0
1
23
NPK-B CHANGE ROOM
2
0
1
24
NPK-B LABOUR TOILET
2
0
2
25
UREA MAINT OFFICE
0
0
1
26
AMMONIA/UREA CONTROL ROOM
3
0
3
27
DAP-PH LABOUR TOILET
2
0
4
28
PH LABOUR TOILET
4
0
5
29
PH MAINT OFFICE
1
0
2
30
UREA PACKER SCALE LABOUR TOILET
1
0
0
31
NPK PACKER SCALE LABOUR TOILET
1
0
0
32
LABOUR CANTEEN
1
1
2
33
NPK-DAP MAINT OFFICE
2
0
2
34
AUTO LABORATORY
1
0
0
35
RAILWAY SIDING (UREA/DAP SIDE)
2
0
2
36
RAILWAY SIDING MARKETING OFFICE
3
0
1
37
RAILWAY SIDING LABOUR TOILET below Mkt office
1
0
1
38
EFFLUENT RECYCLE PLANT
1
0
0
39
SULPHURIC ACID U/L STATION
1
0
0
40
EXCISE OFFICE & CHANGE ROOM
2
0
0
41
LABOUR TIOILET NEAR NEW KCL SILO
4
0
2
42
CONTRACTORS FABRICATION YARD
0
0
3
43
CSO
1
0
0
44
PH-NEHA OFFICE
1
0
1
45
DAP GATE MARKETING/ LOGISTIC OFFICE
1
0
1
46
PH- CONTROL ROOM
1
0
2
71
8
62
TOTAL
KADAM ENVIRONMENTAL CONSULTANTS | SEPTEMBER 2016
242
M/S. ZUARI AGRO CHEMICALS LTD.
7.4
EIA & EMP FOR CUSTOMIZED NPK
FERTILIZERS UNIT, GT, HRSG, AAST
& UREA GRANULATION UNIT
CH-7: ADDITIONAL STUDIES
EHS POLICY OF ZUARI AGRO CHEMICALS LIMITED
KADAM ENVIRONMENTAL CONSULTANTS | SEPTEMBER 2016
243