Provision of dust masks, goggles, safety shoes and helmet. c. Review of health status of workers by maintaining the health record & their occupation. ...

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RISK ASSESSMENT A major emergency in a plant is one which has the potential to cause serious injury or loss of life. It may cause extensive damage to property and serious disruption both inside and outside the plant. Sometimes, it would require the assistance of outside agencies. Emergency may be caused by a number of different factors, e.g. plant failure, it will normally manifest itself in three basic forms, viz., fire, explosion or toxic release. SCOPE The aim of hazard control and disaster management is concerned with preventing accidents through good design, operation, maintenance and inspection, by which it is possible to reduce the risk of an accident, but it is not possible to eliminate it. Since, absolute safety is not achievable, an essential part of major hazard control must also include mitigating the effects of a major accident. An important element of mitigation is emergency planning, i.e. recognizing that accidents are possible, assessing the consequences of such accidents and deciding on the emergency procedures, both onsite and offsite, that would need to be implemented in the event of an emergency. Most major hazard accidents come within the following categories: Events pertaining to the manufacturing process of cement The following areas are identified as hazard prone in case of cement grinding unit where Disaster management plan is required.  Handling of cement  Packing areas

OCCUPATIONAL & SAFETY HAZARDS Occupational and safety Hazards in the cement grinding unit are given below:



Clinker Storage


Storage Clinker

Potential Hazard

Severity Area & Population


of Air Pollution

Clinker Silo Area 5-7 Worker

 Storage Silos are completely sealed structures  Bag filters are provided at Silo top  Pneumatic system is provided for transportation of dust collected from cooler ESPs to mill hopper directly, to avoid the dust transportation

Breakage of Silo Wall

 These are properly designed, taking care of the Load factor  Pre-stress tandons are provided for better load taking  Pressure relief valves are provided on Silo top  Continuous monitor of Silo structure

Storage Storage of Air Pollution Yard Raw Material

Raw Material Storage Yard 4-5 workers

 Storage yards are covered with Shed  Moisture is provided through continuous Water Spray

Packing Plant

Packing Plant 30-35 Workers

 Dust suction ports are provided near the Rotary Packer  Suction ports are provided above the Belt Conveyors  Appropriate PPEs are provided to all workers like Masks, Goggles & Ear Muffs


Packing of Cement in Bags through Rotary Packers

Dust Emission

Type of Hazard Dust  Respiratory Infection  Bronchial Diseases  Gastrointestinal Diseases  Skin Allergy  Pulmonary Disorder Noise  Nausea  Head Aches  Loss of Hearing

Area  Storage Silos  Grinding Mills  Packing Plant

 Grinding  Mills  Packing Plant

Mitigation  Continuous Water Spraying  Sealed Silos  Storing in Covered Areas & Bins  Adequately Designed Bag Filters & Pollution Control Equipment  Adequate Medical Facilities  Continuous Medical Surveillance  Ear Muffs are provided  Greenbelt Corridor is developed along the periphery of the Plant

FUGITIVE DUST CONTROL For control of fugitive dust, water spray arrangement will be provided to spray water all round the fuel stock piles to suppress the dust and to wet the coal while compacting to minimize the dust nuisance. Adequate ventilation and dust suppression systems will be implemented in the coal conveyer system. Installation and operation of water spray nozzles at wagon tippler hopper to reduce the dust emission during unloading of wagons Unloading of material will be carried out with great care by avoiding dropping of material from height, wetting the material by sprinkling water while unloading. FUGITIVE DUST PROTECTION FOR WORKERS NCIL employ all the dust reduction measures for the process units to meet the environmental standards. The following measures are taken up: a. Pre-Employment medical examination of all the workers assessment of fitness for the particular type of work with due regard for adaption


of work place to the worker taking into account individual susceptibility. b. Provision of dust masks, goggles, safety shoes and helmet. c. Review of health status of workers by maintaining the health record & their occupation.