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Environmental Management Plan

The document outlines an environmental management plan for a manufacturing facility. It discusses objectives to treat pollutants and comply with regulations. It also details pollution control measures for air, water, noise, and land environments. These include emissions control systems, wastewater treatment, noise barriers, and hazardous waste disposal. A green belt development plan is also provided to mitigate air and noise pollution through tree planting.

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0% found this document useful (0 votes)

147 views66 pages

Environmental Management Plan

Uploaded by

Amit Banerjee

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Download as PDF, TXT or read online on Scribd

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CHAPTER – 5

ENVIRONMENTAL MANAGEMENT PLAN

5.1 BACKGROUND
The industry shall adopt a comprehensive Environmental Management Plan (EMP) which will cover
several environmental protection measures, not only for abatement of environmental pollution resulting
from the project, but also for the improvement in the ambient environment. The various components of the
EMP are outlined in subsequent sections.

5.2 OBJECTIVES OF ENVIRONMENTAL MANAGEMENT PLAN

The main objectives in formulating the environment management plan are
• To treat all the pollutants, i.e. effluent, air emission, noise & hazardous waste, which contribute to
the degradation of environment, with appropriate technology
• To comply with all the regulations stipulated by central/state pollution control boards related to air
emission and liquid effluents discharge as per Air & water pollution control laws.
• To handle hazardous waste as per Hazardous Waste (Management, Handling and Transboundary
Movement) Rules, 2008 of Environment Protection Act, 1986.
• To encourage, support and conduct development work for the purpose of achieving environment
standards and to improve methods of environment management.
• To promote further forestation in the surrounding areas of the plant.
• To create good working conditions (devoid of air & noise pollution) for employees.
• To reduce fire and accidental hazards.
• Perspective budgeting and allocation of funds for environment management expenditure.
• Dissemination of technological solution on commercial basis to interested parties.
• Continuous development and search for innovative technologies for better environment.
• To adopt cleaner production technology.

5.3 DETAILS OF POLLUTION CONTROL MEASURES

5.3.1 AIR ENVIRONMENT
Emissions at GCPL shall be in the form of the gaseous emission from Thermic Boilers, D. G. Sets etc.
• To reduce emission from Thermic Boiler Air pre heater, cyclone separator, and wet scrubber (All in
series) for each Thermic boiler will be installed. Refer Section 4.3 of Chapter 4.
• Moreover, regular monitoring of stacks and vents shall be carried out to check the emissions.
• Record should be maintained for changing of scrubbing media on printed logbook In case
emissions exceed, the corrective measures should immediately be taken and records of the same
should be maintained.
• Storage of bagasse will be done in separate covered area to prevent its emission in the atmosphere.
• Regular ambient air quality monitoring and stack monitoring shall be carried out within premises
for SPM, RSPM, SO2, NOX,.
• A greenbelt around the factory and plantation within plant will be developed to reduce the air
pollution and attenuation of noise.

5.3.1.1 SOLVENT RECOVERY

No solvent recovery system is required. The process is mixture of all raw materials required for making
MUF resin and no solvent is required.

5.3.2 WATER ENVIRONMENT

• No water will be required in the process of resin manufacturing. Only water required will be for cooling
tower make-up 0.06 KLPD. Water required for particle board manufacturing of around 13.2 KLPD.
Domestic water of around 6.5 KLPD will also be required. Refer Section 4.3 of Chapter 4.

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• The effluent generated from the Particle Board production is mainly for cooling and scrubbing system.
They shall be recycled and reused in cooling and scrubbing system. The company proposes to follow &
set up a “Zero Effluent Discharge” scheme.
• Around 0.06 KLPD of waste water from cooling tower of resin unit, from particle board 0.08 KLPD of
waste water from chilling & 10.0 KLPD scrubbing system will be generated and used in irrigation for
green belt development after treatment.
• Domestic waste water of around 5000 liters/Day will be generated, which will be treated through septic
tank followed by soak pit/well and used in on land irrigation.
• Proper housekeeping shall be adopted to prevent spillages and contaminated surface runoff going to
storm water drains.
• Rain water harvesting will be implemented.

5.3.3 NOISE ENVIRONMENT

The sound pressure level generated by a noise source decreases with increasing distance from the source
due to wave divergence. The impact of the noise can be better understood with the help of Modeling. The
propagation and attenuation of noise pressure wave is dependent on many parameters amongst which, the
medium of travel and the ambient conditions are the most significant parameters.
As per WHO recommendations, there is no risk of damage in hearing due to the noise levels up to 75 dB(A)
(Leq- 8 hrs), whereas OSHA specifies the same as 90 dB(A). The sound pressure levels are used to describe
the exposure to noise in workplace.
• There may be increase the ambient noise level, due to the increased transportation activities and utilities
operation. This creates a slight adverse impact on the sound environment.
• Regular oiling, lubrication and maintenance of the equipment shall be carried out to minimize noise
generation.
The volume of transport vehicles to be handled is very low.
The company shall develop a green belt around the periphery of the premises, which shall act as a barrier to
the propagation of noise from the factory premises. This shall further reduce the noise levels appreciably.
Refer Section 4.3 of Chapter 4.
• It is recommended to measure and maintain records of noise level at various places within and outside
factory premises.
• Manufacturers/ suppliers of major noise generating equipment/ machines like compressors, boilers,
generators should be asked to take required measures for minimizing the noise levels generated by
machines by using noise absorbing material for various enclosures or using appropriate design/
technology for fabricating/ assembling the machines.
• Audiometric tests should be conducted periodically for the employees working close to the high noise
sources.
• Appropriate Personnel Protective Equipments will be provided to workers working near noise sources.

5.3.4 LAND ENVIRONMENT

Solid waste generated from the manufacturing of MUF resin will be degraded resin (gel) which will be
generated due to malfunction for process batch. Degraded resin will be send outside for incineration.
Annexure XIV application for sending waste at M/s GEPIL at Sachin, Surat for landfill as well as
incineration and other waste is Empty bags and drums which will be sell to authorized vendor. Waste
generated is from particle board manufacturing i.e. Dried Ash, Used oil and ETP sludge. These Hazardous
wastes shall be stored in scientifically designed and constructed hazardous waste storage area within the
premises.
• Hazardous waste generation and disposal system due to particle board manufacturing are given in
Table-2.13 of Chapter 2.
• All Necessary precaution shall be taken during handling, loading and unloading of hazardous
waste.

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5.4 GREEN BELT DEVELOPMENT PLAN
M/s. Gujarat Colourlam Pvt. Ltd. will develop a green belt in around 9612.89 sq m around the periphery of
the premises.
Tree plantation is one of the effective remedial measures to control the Air pollution and noise pollution. It
also causes aesthetics and climatologically improvement of area as well as sustains and supports the
biosphere. It is an established fact that trees and vegetation acts as a vast natural sink for the gaseous as well
as particulate air pollutants due to enormous surface area of leaves. It also helps to attenuate the ambient
noise level. Plantation around the pollution sources control the air pollution by filtering the air particulate
and interacting with gaseous pollutant before it reaches to the ground. Tree plantation also acts as buffer
and absorber against accidental release of pollutants.
Each plant shows different air pollution tolerance level depending upon numbers of factors. Air Pollution
Tolerance Index (APTI) is calculated as under,

(T+P)+R
APTI = A
10
Where,
A Ascorbic Acid content mg/gm of dry weight
T Total chlorophyll in mg/gm of fresh weight
P pH of leaf extract
R Relative water content in %

In Green belt area about 1000 tree per acre of land as prescribed by Gujarat Pollution Control Board shall
be planted. Green belt development plan for 5 years is shown in table 5.1.
The selection of tree species suitable for plantation at the industry shall be governed by guiding factors as
stated below
• The trees should be tolerant to air pollutants present in the area
• The trees should be able to grow and thrive on soil of the area, be evergreen, inhabitant, having
minimum of leaf fall.
• The trees should be tall in peripheral curtain plantation and with large and spreading canopy in
primary and secondary attenuation zone.
• It is also recommended to carry out extensive plantation within premises.

TABLE- 5.1 GREEN BELT DEVELOPMENT PLAN FOR 5 YEARS

SR. NO. YEAR NUMBER OF TREE PLANT BUDGET (IN RUPEES)
1 2011 250 12500
2 2012 350 17500
3 2013 500 25000
4 2014 600 30000
5 2015 700 35000

Details of proposed plantation in the plant premises are of following species viz., Terminalia tomentosa,
Pithecellobium dulce (Mithi amli), Azadirachta indica (Limbdo), Syzygium cuminii (Jambhul), Ficus
benghalensis(Bargad), Acacia auriculiformis (Babul), Mangifera indica (Aam), etc.

5.5 RAIN WATER HARVESTING PLAN

Roof top area of any constructed structure, any surface or the paved areas can be treated as catchment as
these areas receive the direct rainfall. Rooftops are the best among them because of the large coefficient of
runoff generated from them and there are less chances of contamination of water.
Conveyance system basically includes rain gutters and down pipes which collects the rain water from
catchment to the storage tank. These rain gutters are usually built during the time of construction. They
need to be designed appropriately as to avoid the loss of water during the conveyance process.

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The most important part of the rain water harvesting is the storage system. The storage system is to be
designed according to the amount of water that is to be stored. An artificial inclined plane should be made
of 4 degree to 7 degree, inclination should drop towards the recharge tube well. Behind that tube well a
thick stop wall having a ball valve at the lowest plane, should be constructed to stop the flow of rain water
and develops an artificial storage near the recharge tubewell. The storage system is to be properly sealed
and does not leak. A tank of 4’x 4’ x 4’ (or bigger size suitable for the user) is to be made around the
recharge tube well. The upper 2 to 3 m of the well casing should be filtered and wrapped with micron or
resin filter. The whole tank should be filled with uniform sized gravel upto the top level. The rain water
stocks towards the bore hole are filtered through the gravel and pass through the micron filter and poured
automatically inside the tube well.

Calculation of available rain water in GCPL - The Area of the industry is divided as under:

Roof Top area (In m2) 5232.5

Paved area (In m2) 4228.63
Open Land (In m2) 6476.89
Green Belt (In m2) 9612.89
Utility and Storage area (In m2) 3384.09
Total Area (In m2) 28935

Average annual rainfall details are as under:

Av. Long term rainfall (1963-07) (mm) 1400
Av. Short term rainfall (1988-09) (mm) 1452

By considering the Long term rainfall average annual rainfall in Surat is 1400 mm.

Considering various use of this industrial area, the rain water which can be stored details of which are as
under:

a Roof top Area : 5860.40 m3/yr (considering 80% of total rainfall water availability during
year)
b Paved Area : 2960.04 m3/ yr (considering 50% of total rainfall water availability during
year)
c Open Land & Green : 6757.71 m3/ yr (considering 30% of total rainfall water availability during
Belt year)

Totally 15578.15 m3/yr rain water will be available for rain water harvesting in the premises of the industry.
This 15578.15 m3/ year rain water can be stored in one lowest corner of the premises by constructing a
Storage tank/pond having capacity of about 4500 m3. The sketch of recharge by roof top harvesting and
collection of rain water in storage tank is shown in figure 5.1.

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FIGURE 5.1 SKETCH OF RECHARGE BY ROOF TOP HARVESTING AND COLLECTION OF
RAIN WATER IN STORAGE TANK

5.6 ENVIRONMENTAL MANAGEMENT CELL (TEAM)

Apart from having an Environmental Management Plan, it is also necessary to have a permanent
organizational set up charged with the task of ensuring effective implementation. In this effect, M/s. Gujarat
Colourlam Private Limited will assign responsibilities to officers from various disciplines to co-ordinate the
activities concerned with management and implementation of environmental control measures. An
organogram of Environmental Management is shown in figure-5.2. Basically, this department undertakes
the monitoring of environmental pollution level by measuring stack emissions, ambient air quality, water
and effluent quality, Noise level, etc. either departmentally or appointing external agency whenever
necessary. M/s. Gujarat Colourlam Private Limited will send the entire required sample for analysis to
recognized laboratory to check the characteristics of parameters.
Regular monitoring will be carried out to ensure that pollution is limited below prescribed limits and will
take corrective action by either providing new equipment or improving the performance pollution control
equipment. In case the monitored results of environment pollution are found to exceed the prescribed limits,
remedial actions are taken through the concerned plant authorities. The actual operation and maintenance of
pollution control equipments of each department is under respective department heads.
The Environmental, Occupational health and Safety department will look after for preparation of
environment statement, carrying out environmental audit, preparation of Water Cess Return and various
consent applications and renewal under water (Prevention and Control of Pollution) Act, 1974 and Air
(Prevention and Control of Pollution) Act, 1981 as well as application for authorization and its renewal
under Hazardous Waste (Management and Handling) Amended Rules, 2003 under Environment Protection
Act, 1986.

FIGURE - 5.2 AN ORGANOGRAM OF ENVIRONMENT MANAGEMENT CELL

GENERAL MANAGER

ENVIRONENT MANAGER

EXECUTIVE

CHEMIST

OPERATORS

M/S. GUJARAT COLOURLAM PVT. LTD, SURAT, GUJARAT 5-5

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5.7 PROPOSED SCHEDULE OF ENVIRONMENTAL MONITORING
Environmental monitoring program is a vital process of any management plan of the development project.
This helps in assessing the potential problems that result from the proposed project, changes in
environmental conditions and effectiveness of implemented mitigation measures. Proposed schedule of
environmental monitoring for the proposed project is given in following table-5.2.

TABLE - 5.2 PROPOSED SCHEDULE OF ENVIRONMENTAL MONITORING

SR. AREA OF SAMPLING PARAMETERS TO BE FREQUENCY
NO. MONITORING LOCATIONS ANALYSED OF SAMPLING
AIR MONITORING
1. Stack Emission process vent SPM, RSPM, SO2, NOx, Once in six month
2. Ambient Air Within plant and two PM2.5, PM10, SO2, NOx, Once in six month
Quality surrounding location in
downward direction
3. Work Zone Storage Area and Formaldehyde Once in a Season
Environment transportation point
SOIL MONITORING
4. Soil Two sampling locations of As per consent of GPCB Once in year
Impact Area
NOISE MONITORING
5. Noise Noise generating units Sound Pressure Levels (Leq) Once Six month
Four sampling locations Sound Pressure Levels (Leq) Once in year
within Plant
5. Liquid effluent 1. Cooling tower blow down Temp, pH, Colour, TSS, TDS, O&G Twice in
2. Treated effluent COD, BOD, Oil & Grease, month,
chloride, sulphides, Sp. Gravity A.N., Ph Compds,
Ammo. Nitrogen, Phenolic TDS and BOD
compounds Once in Week &,
Rest Daily

5.7.1 WASTE-MINIMISATION, RECYCLE/REUSE/RECOVER TECHNIQUES, ENERGY

CONSERVATION, AND NATURAL RESOURCE CONSERVATION

Concept of waste-minimisation, recycle/reuse/recover techniques, energy conservation, and natural resource

conservation is as below.

Waste-minimisation: By using latest technology equipment, Process optimization will be done. Hence,
there is no waste will be generated from the proposed plant except domestic waste. The particle board
manufacturing process itself is utilizing waste from sugar industries and minimising the waste. The process
itself is environment friendly process.

Recycle/reuse/recover: Recycling of water from chilling and scrubber is done.

Energy Conservation Measures: In order to conserve Energy will be provided with translucent sheet to
storage shed, to get natural lighting.

Natural Resource Conservation:

Natural resources like wood and timber are been conserved by using bagasse as raw material for making
laminated particle boards. To conserve ground water rain water harvesting will be carried out to store rain
for future use.

M/S. GUJARAT COLOURLAM PVT. LTD, SURAT, GUJARAT 5-6

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CHAPTER – 6

RISK ASSESSMENT & DISASTER MANAGEMENT PLAN

6.1 INTRODUCTION
Industries have a basic process of manufacturing resin involving consumption, production and storage of
chemicals. The condition that contributes to the danger, by these chemicals, are when these chemicals are
not kept/stable at normal pressure and temperature. Hence these chemicals are kept to be at a cool, dry well-
ventilated location, away from any area where the fire hazard may be acute. Under these circumstances, it is
essential to achieve and maintain high standards of plant integrity through good design, management and
operational controls.
However, accidents do occur and these can cause serious injury to employees or to the public, and damage
to property. Most disastrous events like the Bhopal tragedy have emphasized the need to address both on-
site and off-site safety. The public concern at such events invariably leads to call for additional control at
national and international levels. It is against this background that the various Section and Rules under the
Environment Protection Act, 1986, the Factories Act, 1948 and other Acts specify the requirements for a
safe and reliable working of an industry. These require carrying out various studies and analysis to assess
and mitigate hazards prevalent in the factory in line with the above goal of safe and reliable working. These
are more commonly known as “Risk Assessment Studies”. This chapter explains the basis of Risk
Assessment and its objectives.

6.2 OBJECTIVE OF THE STUDY

The main objectives of the Risk Assessment Studies are as given below:
1) To define and assess emergencies, including risk impact assessment.
2) To control and contain incidents.
3) To safeguard employees and people in vicinity.
4) To minimize damage to property and environment.
5) To establish preventive measures to avoid/ reduce hazards.

6.3 PHILOSOPHY AND METHODOLOGY OF RISK ASSESSMENT

Major hazard installations have to be operated to a very high degree of safety; this is the duty of the
management. In addition, management holds a key role in the organization and implementation of a major
hazard control system. The purpose of which is to understand why accidents occur and how they can be
avoided or at least mitigated. A properly conducted assessment will therefore
i. Analyze the existing safety concept or develop a new one;
ii. Identify the remaining hazards; and
iii. Develop optimum measures for technical and organization protection in event of an abnormal
plant operation.

Quantitative risk assessment:

Hazard potential are quantifies, possible risk is also determined if failure rate data available and then it is
compared with the ‘Permissible Standards’. This will indicate that the permissible limit is lower or higher
than the permissible limit. Based on this, control measures can be decided.

Values of following ‘Hazard Potentials’ can be quantified –

1. Properties of the material
2. Storage parameters
3. Process parameters
4. Manual exposures
5. Visible and measured hazards
6. Transportation hazards
7. Pollution hazards
These values give ‘severity’ part of the risk. Similarly value of “control measures provided” can be
quantified depending on the poor controls to best control.

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Proper classification of good, better and best control measures, is necessary. These values give probability
part of the risk.
Then by using formula, Risk = Severity x Probability, the existing risk level can be calculated and identified
as low, high, higher or highest risk.

6.4 IDENTIFICATION OF HAZARDS

MAJOR HAZARDS
M/s. Gujarat Colourlam Pvt. Ltd would be manufacturing Resin. With the nature of product, organization
will be handling various hazardous materials in the process. Hazard is the associated term with material,
which is a measure or the likely hood of the damage to human working with, or studying the material in
question. All the probable potential hazard is classified under different heads.
1) Fire hazards
2) Toxic gas release hazards
3) Explosion hazards
4) Corrosion hazards

6.4.1 FIRE HAZARDS

Since the Stone Age term 'fire' is associated with fear. It is very dangerous if occurs in uncontrolled manner.
It should be clearly understood that when a liquid is used having flash point below the normal ambient
temperature, it could, in suitable circumstances, liberate a sufficient quantity of vapour to give rise to
flammable mixtures with air.

M/s. Gujarat Colourlam Pvt. Ltd shall be using Flammable chemical (Formaldehyde). Formaldehyde shall
be stored in MS tank not more than 15000 KL. Rule of no smoking will be strictly observed in the
manufacturing or process area.

6.4.2 CORROSION HAZARDS

Corrosion is a chemical reaction-taking place at the surface of metal. The main corrosive chemicals that
will be used are Formaldehyde and Acetic acid etc. These chemicals have their typical hazard when it
comes in contact with human tissues. Most corrosive substances will produce chemical burns, while certain
chemical produce deep ulceration. Other has detailing effect on skin and may cause dermatitis. This has
also adverse effects on weakening the strength of material in contact.

M/s. GCPL will take due care to overcome the hazard. Good quality materials shall be used for transferring
corrosives. Regular thickness testing of equipment, pipelines etc. will be carried out to have the exact
picture of effect of corrosion. Major chemicals that are employed in different processes of GCPL plant,
together with their hazardous characteristics are listed in following table 6.1.
TABLE – 6.1 MAJOR CHEMICALS EMPLOYED IN PROCESSES

S. Name of the Raw Qty Stored Boiling Flash LD50 Oral

No Material (MT) Point (o C) Point (o C) (mg/kg)
1 Formaldehyde 15 X 2 MT 96 60 100 (Rat)
2 Urea 10 MT Decomposes NA 8471 (Rat)
3 Malemine 10 MT NA 93.3 cc 3161 (Rat)
4 Acetic Acid 100 L 118 40 3310 (Rat)
5 Soduim hydroxide 200 L 1390 NIL NIL

NA= Not available

The major hazards in the GCPL described below.

• Fire hazard due to leakage of chemicals like Formaldehyde.
• Electrical hazards due to the electrical major equipment/ machinery, operations, welding, motors,
heavy lift devices, cabling, human intervention (short circuit possibility), maintenance work (due to
machinery breakdown etc.), plant lighting related electrical hazards.

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• Possibility of human injury due to working with mechanical machines, manual handling etc.
• Possibility of injury during chemicals handled, during operations and due to intoxication
• Major dropped objects hazard due to large number of physical handling steps / operations involved
with crane/ overhead lifting/ hoisting equipment.
• Fires in any part of the plant working areas – there is a possibility of rapid escalation if it is not
brought under control quickly.

6.5 DETAILS OF MANUFACTURING PROCESS OF PROPOSED PRODUCTS

Details of manufacturing process of all proposed product are given chapter-2.

6.6 DETAILS OF STORAGE FACILITY

The list of hazardous chemicals with their toxicity level, state, storage and operational details are given in
table-6.3. While toxicity level of hazardous chemicals as per Manufacture, Storage and Import of
Hazardous Chemical (Amendment) Rules, 2000 (MSIHC) is shown in following table-6.2. While
hazards of other type along with safety measures are given in table-6.4 respectively.

TABLE – 6.2 TOXICITY INDEX AS PER MSIHC RULES 2000

DERMAL INHALATION
SR. ORAL TOXICITY
TOXICITY TOXICITY TOXICITY
NO LD50(MG/KG)
LD50(MG/KG) LC50(MG/L)
1. Extremely toxic >5 <40 < 0.5
2. Highly toxic >5-50 >40-200 < 0.5 - 2.0
3. Toxic >50-200 > 200-1000 >2-10

TABLE - 6.3 LIST OF HAZARDOUS CHEMICALS WITH THEIR TOXICITY LEVELS

STORAGE
SR. OPERATION MAH
NAME STATE QTY. ( STORAGE TOXICITY
NO. DETAIL CATEGORY
MT)
1. Formaldehyde Liquid 30 Tank of 15 At NTP Mech. Seal Highly T, F, C
MT pump Toxic
2. Acetic acid Liquid 0.1 In Carboys Transfer by vacuum At Extremely T, F, C, R
– 10 Ltr ambient temp./ At Toxic
NTP drum transfer
pump
Precaution for storage of Formaldehyde:
1. Formaldehyde shall be stored in a tightly closed environment with protection against physical damage,
2. Storage in a cool, dry well-ventilated location, away from any area where the fire hazard may be acute.
3. Outside or detached storage is done for formaldehyde storage. Separate from incompatibles.
4. Containers shall be bonded and grounded for transfers to avoid static sparks.
5. Storage and use areas shall be No Smoking areas.
6. Use non-sparking type tools and equipment, including explosion proof ventilation.
7. Special protective equipment for maintenance break-in or where exposures may exceed established
exposure levels.
8. Training to workers on washing hands, face, forearms and neck while exiting restricted areas.
9. Training to workers on taking shower, disposing of outer clothing, change to clean garments at the end
of the day.
10. Avoiding cross-contamination of street clothes.
11. Washing hands before eating and do not eat, drink, and no smoke in workplace.
12. Protection from freezing.
13. All warnings and precautions listed for the product shall be observed.

Note:
1. Trained industrial worker.
2. Third Party safety audit to find out probable unsafe condition/ cause & to take remedial action.
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TABLE - 6.4 HAZARDS AND ITS CONTROL

Name of the It's effect on
Sr. It’s source & Place of
possible hazard persons property & Control measures provided
No reasons effect
& emergency Environment
1. Fire Transformer Electrical power Transformer * Fire Fighting Equipment's
Transfer oil short failure near power * Graved bed for oil spillage
circuit etc. Production hindrance control or soaking isolated fenced
Loss of transformer centre area
* Lightening arrestor nearby
* DG set for emergency power
supply
2. Fire & Toxic Natural Disaster, Production hindrance Whole * Hydrant system
chemical Earthquakes, Trapping under factory & * First aid available
spillage Lighterning, debris, death population * Smoking prohibited inside
Chemical burn Toxic nearby the factory
Man made war,
chemical spillage * Security at all the time
guarding important locations
3. Fire & smoke Fire in storage Burns Solvent Tank * Adequate earthing Tanker
tank Storage tank catching area unloading permit
fire * Unauthorized person not
Production hindrance allowed to enter
* Breathing Apparatus for
rescue operations
* Alarm system for indicating
unusual incidence

6.7 PROCESS HAZARD AND SAFETY

Process Hazard Analysis
Process Hazard Analysis (PHA) is a method to evaluate and identify credible hazardous scenarios. PHA is
a thorough, orderly, systematic approach for identifying, evaluating, and controlling the hazards of
processes involving hazardous chemicals. Proposed hazardous process details of plant are given in
following table-6.5.

TABLE - 6.5 PROCESS HAZARD AND ITS CONTROL

PARTICULARS CONTROL MEASURE
Name of the Process Resin Mixing - Skill Supervisor
Material involved in process Melamine, Formaldehyde, - Process Safety Information
Urea, NaOH, Acetic Acid - Operating Procedures
- Fire proof electricity fitting
Location Within Plant - Earthing Bonding
Operation details Pressure: ATM - Proper MOC selection
Temperature: 40 - 95 oC - Transportation of raw materials & intermediates
through fix piping
Hazard details Raising in Temperature - Mechanical seal in all pumps and reactors
Manpower involved 1 to 2 person per reactor - Process automation with safety lock

Process Hazard Safety Management:

Process Safety Management is a new discipline covering all aspects of risk and involving the identification,
assessment and control of hazards in process facilities. The hazards most commonly considered include
fires, explosions and release of hazardous substances. Process Safety Management System integrates all
aspects of risks in a facility and puts them under the control of a management system. By establishing a
heightened awareness of the safety impacts of technology, personnel and the management, the system
provides a dynamic environment for continual improvement.

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6.8 RISK ASSESSMENT AND CONSEQUENCE ANALYSIS
In a plant handling hazardous chemicals, the main hazard arises due to storage, handling & use of these
chemicals. If these chemicals are released into the atmosphere, they may cause damage due to resulting
fires or vapour clouds.

Operating Parameters
Potential vapour release for the same material depends significantly on the operating conditions. Especially
for any liquefied gas, the operating conditions are very critical to assess the damage potential.

Inventory
Inventory Analysis is commonly used in understanding the relative hazards and short listing of release
scenarios. Inventory plays an important role in regard to the potential hazard. The potential vapour release
(source strength) depends upon the quantity of liquid release, the properties of the materials and the
operating conditions (pressure, temperature).

Loss of Containment
Plant inventory can get discharged to Environment due to Loss of Containment. Certain features of
materials to be handled at the plant need to the clearly understood to firstly list out all significant release
cases and then to short list release scenarios for a detailed examination. Liquid release can be either
instantaneous or continuous. Failure of a vessel leading to an instantaneous outflow assumes the sudden
appearance of such a major crack that practically all of the contents above the crack shall be released in a
very short time.

6.8.1 SELECTION OF INCIDENTS AND CONSEQUENCE CALCULATIONS

The Consequence Analysis has been done for selected scenarios. This has been done for weather conditions
having wind speed 2.5 m/s. In Consequence Analysis, geographical location of the source of potential
release plays an important role. Consideration of a large number of scenarios in the same geographical
location serves little purpose if the dominant scenario has been identified and duly considered.

SOFTWARE USED FOR CALCULATIONS - ALOHA (AREAL LOCATIONS OF HAZARDOUS

ATMOSPHERES)
Aloha is a computer program designed especially for use by people responding to chemical accidents, as
well as for emergency planning and training. ALOHA can predict the rates at which chemical vapors may
escape into the atmosphere from broken gas pipes, leaking tanks, and evaporating puddles. It can then
predict how a hazardous gas cloud might disperse in the atmosphere after an accidental chemical release.
ALOHA is an air dispersion model, which you can use as a tool for predicting the movement and dispersion
of gases. It predicts pollutant concentrations downwind from the source of a spill, taking into consideration
the physical characteristics of the spilled material. ALOHA also accounts for some of the physical
characteristics of the release site, weather conditions, and the circumstances of the release. Like many
computer programs, it can solve problems rapidly and provide results in a graphic, easy-to-use format. This
can be helpful during an emergency response or planning for such a response.
ALOHA provides output as amount of chemical discharged from the source as well as its concentration in
air it takes in to account different levels of concentrations for a specified chemical. Different concentration
levels are given below:
ERPG 1: is the maximum airborne concentration below which it is believed that nearly all individuals
could be exposed for up to 1 hour without experiencing other than mild transient adverse health effects or
perceiving a clearly defined, objectionable odor.
ERPG 2: is the maximum airborne concentration below which it is believed that nearly all individuals
could be exposed for up to 1 hour without experiencing or developing irreversible or other serious health
effects or symptoms which could impair an individual's ability to take protective action.
ERPG 3: is the maximum airborne concentration below which it is believed that nearly all individuals
could be exposed for up to 1 hour without experiencing or developing life-threatening health effects.
IDLH: The Immediately Dangerous to Life or Health (IDLH) level. A chemical's IDLH is an estimate of
the maximum concentration in the air to which a healthy worker could be exposed without suffering
permanent or escape-impairing health effects.

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6.8.2 SCENARIOS (VULNERABILITY AREA IDENTIFICATION)

Possible accident scenarios at GCPL are given in following table-6.6.

TABLE - 6.6 POSSIBLE ACCIDENT SCENARIOS

CONCENTRATION &
SHORT TYPE
CHEMICAL DAMAGE DISTANCE
DESCRIPTION OF OF PROBABILITY SEVERITY
INVOLVED FROM SOURCE
SCENARIO RISK
(METERS)
Release from damage of Formaldehyde Toxic Very unlikely IDLH 20 ppm
Formaldehyde Storage Effect <3.3 km
tank of 15 MT

Note: To avoid such major accident hazard preventive and mitigation measures for the storage and handling
of hazardous chemicals shall be taken which are given in point no. 6.5.1 on page no. 6-6.

INPUT DATA FOR ALOHA ARE AS BELOW:

Site Data:
Location: Gujarat Colourlam Pvt Ltd, India
Building Air Exchanges Per Hour: 0.60 (Unsheltered Single Storied)
Time: May 30, 2011 1406 Hours St (Using Computer's Clock)

Chemical Data:
Chemical Name: Formaldehyde Molecular Weight: 30.03 G/Mol
AEGL-1(60 Min): 0.9 Ppm AEGL-2(60 Min): 14 ppm AEGL-3(60 Min): 56 ppm
IDLH: 20 ppm LEL: 7 ppm UEL: 73 ppm
Ambient Boiling Point: 95.9° C
Vapor Pressure at Ambient Temperature: 2.20e-005 Atm
Ambient Saturation Concentration: 22.1 ppm Or 0.0022%

Atmospheric Data: (Manual Input of Data)

Wind: 2.47 Meters/second from SW at 3 Mtrs
Ground Roughness: Open Country Cloud Cover: 5 Tenths
Air Temperature: 28.3° C Stability Class: B
No Inversion Height Relative Humidity: 62%

Source Strength:
Leak from Hole In Horizontal Cylindrical Tank
Flammable Chemical Escaping From Tank (Not Burning)
Tank Diameter: 2.15 Meters Tank Length: 4.14 Meters
Tank Volume: 15.0 Cubic Meters
Tank Contains Liquid Internal Temperature: 28.3° C
Chemical Mass in Tank: 118 Tons Tank Is 100% Full
Circular Opening Diameter: 6 Inches
Opening Is 0.1 Meters from Tank Bottom
Ground Type: Concrete
Ground Temperature: Equal to Ambient
Max Puddle Diameter: Unknown
Release Duration: Aloha Limited the Duration To 1 Hour
Max Average Sustained Release Rate: 45 Grams/Min
(Averaged Over a Minute Or More)
Total Amount Released: 1.70 Kilograms
Note: The Chemical Escaped As A Liquid And Formed An Evaporating Puddle.
The Puddle Spread to a Diameter Of 62 Meters.

Source Strength:
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Direct Source: 15 Tons Source Height: 0
Release Duration: 1 Minute
Release Rate: 227 Kilograms/Sec
Total Amount Released: 13,608 Kilograms

The output layout for major release of formaldehyde - toxic effect is shown in figure 6.1 and layout for
major release of formaldehyde - flammable area vapor cloud is shown in figure 6.2.

FIGURE - 6.1 LAYOUT FOR MAJOR RELEASE OF FORMALDEHYDE - TOXIC EFFECT

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FIGURE - 6.2 LAYOUT FOR MAJOR RELEASE OF FORMALDEHYDE- FLAMMABLE
AREA VAPOUR CLOUD

6.9 RECOMMENDATIONS ON THE BASIS OF RISK ASSESSMENT DONE

All precautions would be taken to avoid foreseeable accident like spillage, fire and explosion hazards and to
minimize the effect of any such accident and to combat the emergency at site level in case of emergency.
Some of the preventive safety measures to minimize the risk of accident with respect to Technical Safety,
Organizational Safety and Personal Safety are listed below:
- The factory will take all reasonably practicable measures to minimize the risk of such accident in
compliance with the legal obligation under the relevant safety.
- All building plans and installations are as per relevant acts and duly approved by competent
government authorities.

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- Process and Equipment will be designed by qualified and experienced professionals and fabricated to
applicable national / international codes with stage wise inspection.
- Safety features such as fire extinguisher and suitable Personal Protective Equipment (PPE) shall be
provided. Regular operations and testing of fire extinguishers shall be carried out.
- Periodic inspection and testing of pressure vessels, equipment, machineries and equipment handling
substances.
- Training of workers and Staff for fire fighting, work permit system, first aid, safe handling of materials
and integrating safety, in all activities.
- Accident / Incident reporting system and information of employees about the same for better
awareness.
- Suitable notices / boards displayed at several locations indicating appropriate hazards warning as well
as DOs and DON’T for ensuring operational and personal Safety for information of workers / staff and
visitors.

For the safety of the workers, personal protective equipments like hand gloves, helmets, safety shoes,
goggles, aprons etc. & Ear protecting devices like earplugs/earmuffs will be provided. Nose mask will be
provided at places, where there is possibility of dust generation.

Precautions for storage of Chemicals in drums or bags;

- Separately stored with proper enclosures and marked, within premises in closed shed
- Proper ventilation shall be provided
- Sufficient fire extinguishers and PPE shall be provided
- Flame proof fittings will be provided
- PPE will be used
- Proper earthing bonding
- Contact with skin and eyes will be avoided

6.10 OCCUPATIONAL HEALTH OF THE WORKERS

6.10.1 NOISE EXPOSURE
Sources:
DG sets
Effects:
Hearing impairment, Hypertension, Annoyance, Sleep disturbance
Attenuation And Conservation:
Tools for assessing noise levels A successful noise control program that focuses on engineering control of
noise requires the institution of a hearing conservation plan and the use of proper monitoring equipment,
surveys, maps, and modeling.
A thorough hearing conservation plan should be established where noise exposure exceeds a 85-dBA time
weighted average for eight hours. A good program consists of the following components:
• Noise measurement and analysis;
• Engineering control of noise sources where feasible;
• Administrative controls and personal protection where noise control is not feasible;
• Audiometric testing;
• Employee training and education;
• Record keeping; and
• Evaluation
Control Measures:
• Adopting proper scheduling of construction activities
• Scheduling noisy activities during the daytime periods
• Operating well-maintained mechanical equipment on-site
• Using personnel protection gear such as earplugs, muffs, etc.
• Installing noise barriers around air blowers, pumps, and generators to reduce noise impacts at
nearby receptors

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• Devising and implementing a rigorous inspection and maintenance program applicable to
equipment on-site

6.10.2 HEAT STRESS

Aim is to maintain body core temperature within +1°C of normal (37°C). This core body temperature range
can be exceeded under certain circumstances with selected populations, environmental and physiologic
monitoring, and other controls. Heat stress disorders and possible health effects are shown in table 6.10
Source:
• High temperature and humidity; direct sun or heat; limited air movement; physical exertion; poor physical
condition; some medicines; inadequate tolerance for hot workplaces like working near thermic fluid
heater and insufficient water intake can all lead to heat stress.
Administrative or work practice controls to offset heat effects:
• Provide accurate verbal and written instructions, annual training programs, and other information about
heat stress
• Acclimatize workers by exposing them to work in a hot environment for progressively longer periods.
• Replace fluids by providing cool water or any cool liquid (except alcoholic and caffeinated beverages)
to workers and encourage them to drink small amounts frequently, e.g., one cup every 20 minutes.
Ample supplies of liquids should be placed close to the work area.
• Reduce the physical demands by reducing physical exertion such as excessive lifting, climbing, or
digging with heavy objects. Use relief workers or assign extra workers, and minimize overexertion.
• Provide recovery areas such as air-conditioned enclosures and rooms and provide intermittent rest
periods with water breaks.
• Reschedule hot jobs for the cooler part of the day, and routine maintenance and repair work in hot areas
should be scheduled for the cooler seasons of the year.
• Monitor workers who are at risk of heat stress, such as those wearing semi-permeable or impermeable
clothing when the temperature exceeds 70°F, while working at high energy levels. Personal monitoring
can be done by checking the heart rate, recovery heart rate, and oral temperature.

6.10.3 ILLUMINATION
Illumination standards are shown in table 6.7. The use of energy saving. Power factor lamp fittings shall be
preferred.
TABLE 6.7 ILLUMINATION STANDARDS:
SR.
LOCATION ILLUMINATION BY ILLUMINATION IN LUX
NO.
1. Low roof buildings Fluorescent tube lights 100-150/300(control rooms)
2. Shops/ High roof building HPSV lamps 100-150
3. High color rendering Metal halide lamp fittings -
required(low color distortion)
4. Open yard and area illumination HPSV flood light fittings 15-30

6.10.4 ERGONOMICS
Ergonomics is the term applied to the field that studies and designs the human-machine interface to prevent
illness and injury and to improve work performance. It attempts to ensure that jobs and work tasks are
designed to be compatible with the capabilities of the workers.
Source:
Some physical agents play an important role in ergonomics such as Force, Acceleration and Thermal factors.
Force is an "important causal agent in injuries from lifting. Other Important ergonomic considerations
include work duration, repetition, contact stresses, postures, and psychosocial issues.

Work-Related Musculoskeletal Disorders:

Work-related musculoskeletal disorders (MSDs) are an important occupational health problem that can be
managed using an ergonomics health and safety program. The term musculoskeletal disorders refers to chronic
muscle, tendon, and nerve disorders caused by repetitive exertions, rapid motions, high forces, contact stresses,
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extreme postures, vibration, and/or low temperatures. Other commonly used terms for work-related
musculoskeletal disorders include cumulative trauma disorders (CTDs), repetitive motion illnesses (RMIs),
and repetitive strain injuries (RSIs). Some of these disorders fit established diagnostic criteria such as carpal
tunnel syndrome or tendinitis. Other musculoskeletal disorders may be manifested by nonspecific pain. Some
transient discomfort is normal consequence of work and is unavoidable, but discomfort that persists from day to
day or interferes with activities of work or daily living should not be considered an acceptable outcome of
work.
Control Strategies:
The incidence and severity of MSDs are best controlled by an integrated ergonomics program. Major
program elements include:
• Recognition of the problem,
• Evaluation of suspected jobs for possible risk factors.
• Identification and evaluation of causative factors,
• Involvement of workers as fully informed active participants, and
• Appropriate health care for workers who have developed musculoskeletal disorders.
General programmatic controls should be implemented when risk of MSDs is recognized. These include:
• Education of workers, supervisors, engineers, and managers;
• Early reporting of symptoms by workers; and
• Ongoing surveillance and evaluation of injury, health and medical data, Job-specific controls are directed
to individual jobs associated with MSDs. These include engineering controls and administrative controls.
Personal protection may he appropriate under some limited circumstances.
Control Measures:
Among engineering controls to eliminate or reduce risk factors from the job, the following may be considered:
y Using work, methods engineering, e.g., time study, motion analysis, to eliminate unnecessary motions and
exertions.
y Using mechanical assists to eliminate or reduce exertions required to hold tools and work objects.
y Selecting for designing tools that reduce force requirements, reduce holding time, and improve postures.
y Providing user-adjustable workstations that reduce reaching and improve postures.
y Implementing quality control and maintenance programs that reduce unnecessary forces and exertions,
especially associated with non value-added work.
Administrative controls reduce risk through reduction of exposure time and sharing the exposure among a larger
group of workers. Examples include:
y Implementing work standards that permit workers to pause or stretch as necessary but at least once per
hour.
y Re-allocating work assignments (e.g., using worker rotation or work enlargement) so that a worker does
not spend an entire work shift per forming high-demand tasks.
Due to the complex nature of musculoskeletal disorders, there is no "one size fits all" approach to reducing the
incidence and severity of cases. The following principles apply to selecting actions:
y Appropriate engineering and administrative controls will vary from industry to industry and company to
company.
y Informed professional judgment is required to select the appropriate control measures.
y Work-related MSDs typically require periods of weeks to months for recovery. Control measures should
be evaluated accordingly to determine their effectiveness.

6.10.5 OCCUPATIONAL HEALTH AND SAFETY PROGRAM FOR THE PROJECT

Health hazards associated with the occupation are called occupational hazards. In chemical industry due to
handling of toxic and hazardous chemicals there are possibilities of developing occupational diseases. M/s
M/s. Gujarat Colourlam Pvt. Ltd shall carry out the following checks to curb the problem:
i) Pre - employment medical check up at the time of employment.
ii) Annual medical check up shall be done for all employees.
1. <30 Once in five years
2. 31-40 Once in four years
3. 41-50 Once in two years
4. Above >50 years once every year

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iii) First aid training shall be given to the employees.
iv) Monitoring of occupational hazards like noise, ventilation, chemical exposure shall be carried out at
frequent intervals, the records of which shall be documented.
v) Evaluation of health of workers viz. chest x ray, Audiometry, Spirometry Vision testing (Far &
Near vision, colour vision and any other ocular defect) ECG, during pre-employment and periodical
examinations shall be carried out.

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CHAPTER - 7

PROJECT BENEFITS
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CHAPTER – 7
PROJECT BENEFITS
7.1 INTRODUCTION
Particleboard is a classic wood-based panel, made from high quality particles of wood/bagasse.
Particleboard Plants are specially designed to produce an effective alternative for wood-based panel
products. This industry meets the objectives of conserving forest resources. Particle Board is eligible for
labeling as an endesign exonmental – friendly product to be known as ECO-mark for wood substitutes,
published in the Gazette of Government of India.
Keeping in mind the phenomenal growth of Particle Board markets both domestic and global, M/s. Gujarat
Colourlam Pvt. Ltd proposes to set up Bagasse based Particle Board and Captive Resin manufacturing unit.

7.2 PHYSICAL INFRASTRUCTURE

As a proposed project is a new project, all the major physical infrastructure is development shall take place,
which will improve the existing infrastructure scenario.

7.3 EMPLOYMENT OPPORTUNITIES

Skilled and unskilled manpower will be needed. This will temporarily increase the employment
opportunity. Secondary jobs are also bound to be generated to provide day-to-day needs and services to the
work force. This will also temporarily increase the demand for essential daily utilities in the local market.

The manpower requirement for the proposed project will generate some permanent jobs and secondary jobs
for the operation and maintenance of plant. Proposed requirements of manpower are given in following
table-7.1. This will increase direct / indirect employment opportunities and ancillary business development
to some extent for the local population. This phase is expected to create a beneficial impact on the local
socio-economic environment.

The project will benefit the people living in the neighboring villages by giving preference to them in
relation to direct employment associated with the various project activities. Construction and operation
phase of the proposed project will involve a certain number of laborers. There is a possibility that local
people will be engaged for this purpose. The operation phase will involve a number of skilled and unskilled
workers. There is a possibility that local people will be engaged for this purpose to the extent possible and
hence improve the existing employment scenario of the region.

TABLE - 7.1 PROPOSDED MANPOWER REQUIREMENT

Sr. Appointed as a
No. Of Person in No. Of Shift Total Person
No. Labour Staff
1. 1st Shift 18 9 27
2. 2nd Shift 16 3 19
3. 3rd Shift 16 3 19
Total: 65

7.4 INDUSTRIES
The required raw materials and skilled and unskilled laborers will be utilized maximum from the local area.
The increasing industrial activity will boost the commercial and economical status of the locality, to some
extent.

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CHAPTER – 8

CONSULTANT ENGAGED
Environmental Impact Assessment Study for the proposed Resin Manufacturing Unit (1000 TPD) of M/s.
Gujarat Colourlam Pvt Ltd conducted by,
Name : M/s. Envision Enviro Engineers Pvt. Ltd.
Address : 208, G-Tower, Shankheshwar Complex,
Above Girish Group of Hospitals, Sagrampura,
Surat-395 002, Gujarat.
Phone : (0261) 2470653, 2472374, 2473905
Fax : 91-261-2478518
E-mail : eia@en-vision.in
Website : en-vision.in
Status of accreditation with : Provisional Accreditation from QCI/NABET
QCI/NABET awaited
Serial No. in QCI list : 80th
M/s. En-vision Enviro Engineers Pvt. Ltd. (ISO 9001:2008 certified company) is a consulting,
engineering and equipment supplier firm delivering exceptional service and quality to public and private
clients in India. En-vision is working with zeal in the field of environmental engineering for more than 15
years. En-vision has a vision of supporting and being a part of development that is sustainable to our
environment.
En-vision is one of the leading companies as Environmental Consultants providing the EIA study required
for Environmental Clearance from MoEF/DoEF and NOC (Consent to establish), CCA (Consent to
Operate) from Pollution Control Board. En-vision has a well established laboratory with environmental
monitoring and analysis of environmental parameters (Air & Water monitoring, Waste Water analysis,
Stack analysis).
En-vision is also working as consultants, turnkey project executors and equipment suppliers in the
field of Pollution Control (Environmental) Engineering and deals with turnkey projects in Incineration
System for Solid and Hazardous waste. En-vision also does the Design, construction, erection and
commission of Water Treatment Facility (Effluent treatment plants, Sewage treatment plants, etc.) and
Secured Landfill sites.
En-vision is enlisted contractor with PWD, Goa as Class-I-A (One-A) in the category of Water
Supply & Waste Water Disposal. En-vision is recognized as Environmental Auditors and enlisted as
consultants and pollution control equipment suppliers with Gujarat Pollution Control Board. Provide
Services in the field of Structural Engineering, Water Supply Engineering and Civil Engineering. It has
national cliental from state of Gujarat, Chhattisgarh, Assam, Haryana, Andra Pradesh, Rajesthan, Goa, etc
and international cliental from Dubai and Egypt.
EEEPL is Member of Consulting Engineers Association of India, Indo-German Chamber of
Commerce, Society of Environmental Auditors and Consultants, Ahmedabad and Member of CII. EEEPL is
operated by Mr. Nihar Doctor and Mr. Kunhal Shah, who are actively involved in achieving their vision to
be a significant contributor in the development sustainable by Environment using collective technical
acumen to provide services & equipments and be a part of movement of building Modern India with better
environment and safety aim.

Mr. Nihar Doctor: He possesses Bachelor’s degree in Civil Engineering and Master’s Degree exclusively
in the specialized field of structural Engineering as well as Environmental Engineering. Presently he is
holding the position of Director in M/s. Envision Enviro Engineers Pvt. Ltd. He is having fourteen years
experience in Environmental Engineering field.

Mr. Kunhal Shah: He possesses Bachelor’s degree in Civil Engineering and Master’s Degree exclusively
in the specialized field of Environmental Engineering. Presently he is holding the position of Director in

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M/s. Envision Enviro Engineers Pvt. Ltd. He is having eighteen years experience in Environmental
Engineering field. Functional area experts involved in the Environment Impact Assessment study for M/s.
Gujarat Colourlam Pvt. Ltd are shown in as below:
1. Mr. Nihar Doctor (M.E. Env & Struct. Engg., B.E. Civil) Coordinator, FAE (SHW; AQ; WP)
2. Mr. Kunhal Shah (M.E. Env, B.E. Civil) FAE (WP; AP; Noise)
3. Mr. Jignesh Patel (M.Sc. Material Sci, B.Sc. Chemistry) FAE (AQ; RH)
4. Mr. Mansoor Alam (M.Sc. Env. Bot) FAE (EB)
5. Ms. Krupali Kotadia (MIHS) FAE (RH)
6. Mr. Krunal Patel (B.Sc. Chemistry) Assit. FAE (AQ)
7. Mr. Ankit Vyas (B.E. Chem.) Assit. FAE (SHW)
8. Mr. Deepak Maru (B.E. Chem.) Assit. FAE (AP)
9. Ms. Alifiya Motorwala (M.E. Env.) Assit. FAE (WP)
10. Mr. Pravin Singh (M.Sc. Env.) Assit. FAE (EB)
11. Mr. Ashish Upadhaya (M.Sc. Geomatics) Assit. FAE (LU)
12. Mrs. Sheetal Tamakuwala (PhD. Sociology, M.A. Sociology) FAE (SE)
13. Mr. Harsh Smart (M.Sc. Org) Monitoring Incharge (AP; WP)
14. Ms. Riddhi Shah (M.Sc. Org) Lab Chemist (AP; WP)
15. Mr. Murtaza hazoori (M.Sc. Bio informatics) Assit. FAE (EB)

Active involvement from Mr. Omprakash Agarwal and Mr. Amit Agarwal from GCPL has helped in
preparation of EIA report. Project EIA report is been reviewed by Kunhal Shah (Director) and approved
Project Coordinator Mr. Nihar Doctor (Director).

Laboratory for Analysis:

1. Envision Enviro Engg. Pvt. Ltd. Monitoring and Analysis; Applied for NABL certification
2. Pollucon laboratories Analysis of heavy metal in water and soil analysis; NABL certified laboratory
vide Certificate Nos T-0820

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ANNEXURE – I
TERMS OF REFERENCE LETTER AWARDED BY EAC (INDUSTRY-I)

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ANNEXURE – I (CONT.)

M/S. GUJARAT COLOURLAM PVT. LTD, SURAT, GUJARAT A- 2

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ANNEXURE – I (CONT.)

M/S. GUJARAT COLOURLAM PVT. LTD, SURAT, GUJARAT A- 3

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ANNEXURE – I (CONT.)

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ANNEXURE – II
COMPLIANCE STATUS OF TOR

S.N. TERMS OF REFERENCE COMPLIANCE

1. Executive summary of the project Refer Executive Summary.
2. Justification of the project. Refer section 2.2 on page no. 2-2
of chapter-2
3. Promoters and their back ground. Refer section 2.3 on page no. 2-2
of chapter-2
4. Regulatory framework Refer table 2.3 on page no. 2-4 of
chapter-2
5. A map indicating location of the project and distance from Refer figure 2.2 on page no. 2-6
severely polluted area of chapter-2
6. Project location and plant layout. Refer figure 2.3 on page no. 2-7
and page no. 2-8 of chapter-2
7. Infrastructure facilities including power sources. Refer section 2.7 on page no. 2-
13 of chapter-2
8. Total cost of the project alongwith total capital cost and Refer section 2.4 on page no. 2-3
recurring cost/annum for environmental pollution control of chapter-2
measures.
9. Project site location alongwith site map of 10 km area and Refer figure 3.1 on page no. 3-2
site details providing various industries, surface water of chapter-3 and Section 3.15 on
bodies, forests etc. page no. 3-36 of chapter-3
10. Present land use based on satellite imagery for the study area Refer figure 3.7 and 3.8 on page
of 10 km radius. no. 3-20 and 3-22 of chapter-3
11. Location of National Park/Wild life sanctuary/Reserve There is no National Park/Wild
Forest within 10 km radius of the project. Life Sanctuary/Reserve Forest
within 10 km radius of the
project.
12. Details of the total land and break-up of the land use for Refer table 2.7.1 on page no. 2-11
green belt and other uses. of chapter-2
13. List of products along with the production capacities. Refer table 2.1 on page no. 2-2 of
chapter-2
14. Detailed list of raw material required and source, mode of Refer table 2.5 on page no. 2-9 of
storage and transportation. chapter-2
15. Manufacturing process details along with the chemical Refer section 2.6.3.2 on page no.
reactions and process flow chart. 2-10 of chapter-2
16. Site-specific micro-meteorological data using temperature, Refer section 3.4 on page no. 3-4
relative humidity, hourly wind speed and direction and of chapter-3
rainfall is necessary.
17. Ambient air quality monitoring at 6 locations within the Refer figure 3.3 on page no. 3-6
study area of 5 km., aerial coverage from project site as per of chapter-3
NAAQES notified on 16th September, 2009. Location of
two AAQMS in downwind direction.
18. One season site-specific micro-meteorological data using Refer section 3.4 on page no. 3-4
temperature, relative humidity, hourly wind speed and of chapter-3, section 3.6 on page

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ANNEXURE – II (CONT.)

S.N. TERMS OF REFERENCE COMPLIANCE

and rainfall and AAQ data (except monsoon) for PM10, SO2, NOx on page no. 3-6 of chapter-3,
including VOCs should be collected. The monitoring stations section 3.7 on page no. 3-10 of
should take into account the pre-dominant wind direction, chapter-3 and section 3.8 on
population zone and sensitive receptors including reserved forests. page no. 3-13 of chapter-3
Data for water and noise monitoring should also be included.
19. Air pollution control measures proposed for the effective control Refer section 4.3 on page no.
of gaseous emissions within permissible limits. 4-6 of chapter-4
20. Name of all the solvents to be used in the process and details of There will be no solvents used
solvent recovery system. in the process and therefore no
recovery system for the
solvents. Refer section 2.6.3.1.
on page no. 2-9 of chapter-2
21. Design details of ETP, incinerator, if any along with control of Refer section 4.3 on page no.
Dioxin & Furan, boiler, scrubbers/bag filters etc. 4-6 of chapter-4 and section
4.4 on page no. 4-11of
chapter-4
22. Details of water and air pollution and its mitigation plan Refer section 4.3 on page no.
4-6 of chapter-4, section 4.4
on page no. 4-11 of chapter-4,
section 5.3.1 on page no. 5-1
of chapter-5 and section 5.3.2
on page no. 5-2 of chapter-5
23. Action plan to control ambient air quality as per NAAQES Refer section 5.7 and table 5.2
Standards notified by the Ministry on 16th September, 2009. on page no. 5-5 of chapter-5
24. An action plan to control and monitor secondary fugitive Refer section 4.3.3 on page no.
emissions from all the sources as per the latest permissible limits 4-11 of chapter-4
issued by the Ministry vide G.S.R. 414(E) dated 30th May, 2008.
25. Determination of atmospheric inversion level at the project site Refer figure 4.2 on page no. 4-
and assessment of ground level concentration of pollutants from 8 of chapter-4
the stack emission based on site-specific meteorological features.
Air quality modelling for proposed plant.
26. Permission for the drawl of 1.3 m3/day water from the concerned Refer figure 2.4 on page no. 2-
authority. Water balance chart including quantity of effluent 12 and 2.8.1 on page no. 2-14
generated recycled and reused and discharged. of chapter-2 & Annexure-V
&XVI
27. Action plan for Zero Discharge of effluent should be included. Refer section 2.8.1.1 on page
no. 2-14 of chapter-2 and
section 5.3.2 on page no. 5-2
of chapter-5
28. Ground water quality monitoring minimum at 6 locations should Refer section 3.7.1 on page no.
be carried out. 3-10 of chapter-3
29. The details of solid and hazardous wastes generation, storage, Refer section 2.8.4 on page no.
utilization and disposal particularly related to the hazardous waste 2-16 of chapter-2 & section
calorific value of hazardous waste and detailed characteristic of 4.4.2 on page no. 4-12 of
the hazardous waste. Action plan for the disposal of fly ash chapter-4. Calorific value of
generated from boiler should be included. hazardous waste - NA

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30. Precautions to be taken during storage and transportation of Refer table-6.3 on page no. 6-4
hazardous chemicals should be clearly mentioned and of chapter-6
incorporated.
31. A copy of the Memorandum of Understanding signed with Not applicable
cement manufacturers indicating clearly that they will utilized
all the organic solid waste generated.
32. Details of captive land fill along with design details as per Refer section 4.5.2 on page no.
CPCB guidelines, if applicable. Location of secured land 4-12 of Chapter 4, Table 3.6
fill/TSDF. Ground water monitoring around the project site as on page no. 3-12 of Chapter 3.
well as around land fill site
33. Authorization/Membership for the disposal of liquid effluent in Refer section 2.8.1.1 on page
CETP and solid/hazardous waste in TSDF. no. 2-16 and section 2.8.4 on
page no. 2-18 of chapter-2.
Annexure XIV on page no 42.
34. List of hazardous chemicals (as per MSIHC rule) with toxicity Refer table-6.3 on page no. 6-4
levels. of chapter-6
35. Risk assessment for storage for chemicals/solvents and Phosgene and Cyanide are not
phosgenes. Action plan for handling & safety system, whenever involved in the process so
any cyanide is involved in process. there is no handling & safety
system for the Phosgene and
Cyanide. Refer section 6.6 on
page no. 6-4 of chapter-6.
36. A note on arrangement for monitoring Phenol Formaldehyde in Phenol formaldehyde will not
the work zone. be used in the process. For
formaldehyde refer section
5.7, table 5.2 on page no. 5-5
of chapter-5.
37. An action plan to develop green belt in 33 % area Refer section 5.4 on page no.
5-2 of chapter-5
38. Action plan for rainwater harvesting measures at plant site Refer section 5.5 on page no.
should be included to harvest rainwater from the roof tops and 5-3 of chapter-5
storm water drains to recharge the ground water.
39. Occupational health of the workers needs elaboration including Refer section 6.10 on page no.
evaluation of noise, heat, illumination, dust, any other 6-10 of chapter-6
chemicals, metals being suspected in environment and going
into body of workers either through inhalation, ingestion or
through skin absorption and steps taken to avoid musculo-
skeletal disorders (MSD), backache, pain in minor and major
joints, fatigue etc. Occupational hazards specific pre-placement
and periodical monitoring should be carried out.
40. Socio-economic development activities should be in place. Refer section 3-12 on page no.
3-24 of chapter-3
41. Detailed Environment management Plan (EMP) with specific Refer chapter-5 on page no. 5-
reference to details of air pollution control system, water & 1
wastewater management, monitoring frequency, responsibility
and time bound implementation plan for mitigation measure

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should be provided.
42. EMP should include the concept of waste-minimization, Refer Section 5.7.1 on Page
recycle / reuse / recover techniques, Energy conservation, and no. 5-6 of Chapter-5
natural resource conservation.
43. Any litigation pending against the project and/or any There is no litigation pending
direction/order passed by any Court of Law against the project, against the proposed project
if so, details thereof. and/or director. Undertaking in
Annexure XV
44. Public hearing issues raised and commitments made by the Will be incorporated after
project proponent on the same should be included separately in public hearing.
EIA/EMP Report in the form of tabular chart with financial
budget for complying with the commitments made.
45. A tabular chart with index for point wise compliance of above Refer a Tabular Chart of the
TORs. TORS and Compliance Index
The following general points should be noted:
i. All documents should be properly indexed, page numbered. Noted
ii. Period/date of data collection should be clearly indicated. Noted
iii. Authenticated English translation of all material provided in Noted
Regional languages.
iv. The letter/application for EC should quote the MOEF file No. Noted
and also attach a copy of the letter.
v. The copy of the letter received from the Ministry should be Noted
also attached as an annexure to the final EIA-EMP Report.
vi. The final EIA-EMP report submitted to the Ministry must Noted
incorporate the issues in this letter. The index of the final EIA-
EMP report must indicate the specific chapter and page no. of
the EIA-EMP Report.
vii. While preparing the EIA report, the instructions for the Noted
proponents and instructions for the consultants issued by MoEF
vide O.M. No. J-11013/41/2006-IA.II (I) dated 4th August,
2009, which are available on the website of this Ministry
should also be followed.
viii. The consultants involved in the preparation of EIA/EMP report Noted
after accreditation with Quality Council of India
(QCl)/National Accreditation Board of Education and Training
(NABET) would need to include a certificate in this regard in
the EIA/EMP reports prepared by them and data provided by
other organization/Laboratories including their status of
approvals etc. In this regard circular no. J l1013/77/2004-IA
II(I) dated 2nd December, 2009 posted on the Ministry’s
website http://www.moef.nic.in may be referred.
ix. Certificate of Accreditation issued by the QCI to the Noted
environmental consultant should be included.