EXECUTIVE SUMMARY

Submitted by:

Walchandnagar Industries Limited

REIA FOR MANUFACTURING OF EQUIPMENT, STRUCTURES AND VESSELS FOR MARINE & ENERGY SECTORS ‐ WIL, DAHEJ 

 

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Executive Summary

Walchandnagar Industries Limited (WIL) has completed 100 years of engineering excellence

and is predominantly engaged in the manufacture of heavy engineering equipment and

components required for various industries. The main production facilities are located at

Walchandnagar in Maharashtra with some additional facilities at Satara and Dharwad. In the past

few years, the company has expanded its activities into a number of strategic areas like

aerospace, defence, nuclear power plants etc.

The current project being planned at Dahej would be an extension of the parent facility and will

predominantly focus on the manufacture of heavy equipment, structures and components for the

various segments of business already being pursued by the company. The current industrial trend

reveals that, in future, the size of structures and equipment would increase phenomenally,

requiring waterfront facilities for their erection and transportation to various destinations. Such a

waterfront facility could also then be used for fabrication and loading out offshore platforms

which includes, Jackets, Decks, Manifolds, Equipment packages, Helidecks etc. The project,

therefore, would evolve as a major engineering facility involving fabrication of heavy structures,

machining of high end engineering equipment and components. Once established, the

manufacture may be extended to include sophisticated surface and sub-surface vessels.

The River Narmada joins the Gulf of Khambhath on its eastern bank at Dahej. The estuarine

region at the mouth as well as the adjoining area is naturally demarcated with large tidal flats.

During low tide, vast stretches of intertidal area are visible in the estuary. Good depths are

available at the mouth of the river but sand bars and shallow patches are more prevalent inside

the river and navigation inside the river is possible only during high tide. The pre-monsoon

period (spring) from April to May. The month of May being the hottest. The south-west

monsoon prevailing from June to September with mainly south-westerly winds and the post

monsoon period (autumn) from October to March with North-easterly winds. The annual rainfall

in the area is approximately 1200 mm, 94% of which occurs in the months of June, July, August

and September.

In order to tap this opportunity and meet the demand, WIL has decided to create a suitable

manufacturing and assembling facility that will primarily cater to the following markets:

 

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• Offshore Platforms and Structures

• Onshore Drilling Rigs & Offshore Derricks

• Heavy Engineering items required by various industries

• Components for Power Generation Plants.

• Components for Heavy Duty Boilers and other such machinery

• Testing Equipments related to Energy Sector

• Surface and subsurface structures and vessels

a) Barges both driven and self-propelled

b) Subsea manifolds and structures

c) Ocean going vessels.

Location of the proposed facility on the right bank of river Narmada

 

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As described above this is a fabrication unit, thus the main raw material are steel, paints,

primers, solvents, acetylene, oxygen, LPG and HSD for DG sets. The final finished

products are various structures and equipment described in sections above. The details of

tonnage of various raw materials are as follows:

S. No. Item Quantity

i. Steel 28385 tonnes

ii. Paint 1760 cum (in 88 containers of 20 litre capacity each)

iii. Oxygen 9240 cum (in 1320 cylinders)

iv. Acetylene 1320 cum (in 220 cylinders)

v. LPG 10000 cylinders

vi. HSD 4800 l (2 days supply for DG sets consuming 50 l/hr)

The workshops for manufacturing equipment for Energy sectors and other heavy

engineering projects would be located in plot no.42. Plot no.38 and 43, which are

continuous and bigger would house all fabrication shops for offshore structures, offices

and other utilities. The leveled and compacted open fabrication yard will cater to the

heavy loads of structures to be manufactured and movement of heavy duty cranes.

Infrastructure like sub-station, water tanks etc. will be provided in plot no.43 and also in

plot no.42. General purpose fabrication and machining facility would be created in plot

no.44. The workshops for manufacturing equipment for Energy sectors and other heavy

engineering projects would be located in plot no.42. Plot no.38 and 43, which are

continuous and bigger would house all fabrication shops for offshore structures, offices

and other utilities. The leveled and compacted open fabrication yard will cater to the

heavy loads of structures to be manufactured and movement of heavy duty cranes.

Infrastructure like sub-station, water tanks etc. will be provided in plot no.43 and also in

plot no.42. General purpose fabrication and machining facility would be created in plot

no.44.

 

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Activities will take place in the workshops, under the building and in the open yard. The

operations carried out on the workshop building are gas cutting, welding, machining,

milling, grinding, heat treatment, grit blasting, washing, cleaning etc. Though these

operations are not heavy water consumptive, some indicative water requirement is

considered. The water requirement for the operations being carried out in open yard is

almost nil except washing & cleaning. However some requirements that are considered

obvious for workshop of this huge capacity such as:

• Cooling requirement for machines and electric equipments

• Make up water requirement for generator set and compressors cooling system

• Backwash requirement for air filter cleaning

• Service water requirement for cleaning & washing for the operations in open yard

The water requirement per day is as follows:

S. No. Particular Quantity

(KL/day)

A Industrial Water use

i. Make-up water for cooling towers & similar processes 20

ii. Once through cooling for compressors & pumps 20

iii. Process use for washing & cleaning 12

iv. General washing, sanitation & maintenance 8

B Domestic Water Use

i. Food preparation & dish washing area 20

ii. Washing & toilet blocks 12

iii. Security & administrative blocks 10

C Outdoor water use

i. Landscape & gardening requirement 20

ii. Open yard water requirements 10

Approximate leaks in the system 30

Add 10 % excess 16

Total service water requirement 178

 

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E Waste water generation 77

F Amount of Treated waste water 61

G Reuse of Treated water ( For Gardening and Flushing) 40

Net Fresh water Demand 178-40 = 138

Source: As provided by WIL

The water is sourced from GIDC (350 mm diameter pipeline existing water connection in

front of WIL plot).

In order to assess the existing health of the Narmada Estuary, along its coast where the

proposed facilities is to be developed, four sampling stations were selected in the

Narmada estuary and one station near the mouth of the Gulf. The analyses results showed

that temperature of water column was in the range of 25-270C during the sampling

period. The pH of the water column of the estuary was found to be slightly acidic to

nearly alkaline and it varies from 6.73 – 7.09. The recorded value of salinity was 19.7-

32.1 ppt. Dissolved oxygen (DO) content from the surveyed stations varied from 5.3-6.8

mg/L. The concentration of DO was found to be good as expected because of regular

mixing of sea water. The total Nitrogen level was found to be very high from the analysis

and varied from 5.39 to 8.93 mg/L. The phosphate level was varying from 1.42 and 2.05

mg/L. The Ammonia contents were found to be in between 1.17 and 2.23. The nitrate

level was varied between 1.98 and 2.51 mg/L. From this it can be concluded that there is

no shortage of supply of nitrogen , phosphorous and nitrate in the estuary. TSS value was

varying from 587-1052 mg/L. Published document (GES report on Coastal and Maritime

Environments of Gujarat) has also confirmed that the river Narmada annually carries 50

MT of TSS to the Gulf. Heavy silt load obviously makes the Gulf water highly turbid

with almost zero water column visibility. Bed-sediments were collected from four

locations from the surveyed area. Parameters like pH, texture and heavy metals

chromium, mercury, copper, lead, cadmium, zinc and manganese. The bed-sediment

found to be alkaline in nature. As discussed earlier the texture of the bed-sediment was

silty clay. Heavy metal content was also low. As far as the marine biological analysis is

concerned, the Phytoplankton’s were represented by six groups. Due to the very low

primary productivity their density was very low. No rare or endangered groups of

 

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phytoplankton were found in the area. Gross primary productivity values ranged from 0.2

to 0.5 gC/m2/day and net primary productivity values ranged from 0.1 to 0.2 g C /m2 /m2

/d. The density of the phytoplankton group is very low due to the very low light

penetration and high turbidity. The Zooplankton was also represented by 6 groups. The

total density of zooplankton was also very low. In the case of Zooplankton also, no rare,

threatened or endangered species of zooplankton were found. Diversity and abundance of

meiofauna and benthic macrofauna were very low. No endangered or rare groups are

present in the area. No bivalves were also found. Benthic faunal population in an

environment depends on the nature of the substratum and the organic matter content of

the substratum.

Commercial fishing operation takes place only during the monsoon. Other than monsoon

no fishing prevails in the Narmada estuary. A few boats owners reside in nearby villages

in Jageshwar, Ambhetha, Luhara and Suva and they engage themselves in fishing only

during monsoon. The main contribution from this area towards fisheries potential is

through the fishes and crabs. Fish landing centres around the Gulf of Khambhath account

for only 2.1% of the State total- majority of which takes place on its eastern shores.

Beacuse of high suspended load and strong tidal currents no demersal fishery exists in the

Gulf. Whatever fishery is possible is all pelagic. The Gulf serves as the migratory route

for the clupeid hilsa (Tenualosa ilisha) on their way to the Narmada river for breeding

and the outward route for the newly hatched juveniles and some of the adults.

The SPM level was observed in the monitoring stations ranged between 135.5 μg/m3and

165.1 μg/m3. Industrial and commercial activities, constructions, movement of heavy

trucks and mostly un-tarred roads are the major sources of generation of SPM around the

study area. Although the surveyed area fall under industrial zone the SPM level observed

in these stations do not even exceed the limits set for the rural /residential zone. RSPM

levels were found ranging from 61.6 to 69.9 μg/m3. This was also found to be within the

prescribed standards for industrial as well as rural and residential zone ( as per earlier

MoEF Notification). The concentration for SO2 were analysed between 18.0 and 30.0

μg/m3. The NOx level ranged in between 16 μg/m3and 24μg/m3. The main source of SO2

and NOx emission is vehicular & industrial sources.

 

 

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largest among them with a population of 3756 of 1551 households. Dahej is followed by

Lakhigam witha population of 3357 from 640 households. Jageshwar, Ambhetha,

Vengani and Luhara are small villages with a population of 1465 (from 346 hh), 1330

(from 293 hh) , 675 ( from 150 hh), 1393 ( from 276) respectively. The nearest town is

Bharuch which is district head quarters fifty km from the proposed site. As far as literacy

arte is concerned the average literacy rate in all these surveyed villages was 60% which is

found to be very impressive. Every village has a primary school and for high education

students depend on Dahej. No college is located in this area. During the survey it was

observed that one more high school is under construction in Jageshwar village. Medical

facility does almost not exist in these villages except at the nearest town Bharuch.

Most of the villagers in the surveyed area are engaged in nearby industries and other

petty jobs. Farming is not considered as a livelihood support system for the villagers for

reasons like the non availability of land ( most of the lands being sold to GIDC) and not

suitable for farming (lack of irrigation facility and less fertile soil). Although the villages

are surrounded by industries by none other than Reliance Petrochemicals, LNG Petronet,

Gujarat Fertilizer Corporation Limited, ABG Shipyard and other small big units, the

socio-economic condition of the villagers were not found so sound. The basic amenities

such as health care, education and drinking water facility were grossly neglected areas in

the study area. Though some of the industries came forward to solve at least the drinking

water issue in this region is a commendable effort.

Water , air and noise pollution, accumulations of solid and hazardous waste and point and

non-point pollution can occur simultaneously with the variety of operations that occur at

these facilities. Being a water front project, the maximum impact due to the proposed

project shall be on the marine/coastal environment as stated earlier.

Potential sources of pollution that may impact on water quality in the area include:

i. Soil runoff from the project may lead to off-site contamination (particularly

during rainy season).

 

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ii. Improper disposal of construction debris may lead to off-site contamination of

water resources.

iii. Unaccounted disposal of domestic wastewater from temporary labour camps.

iv. Discharge of oil/grease/lubricants from the vehicles/construction equipments and

wastewater stream generated from activities such as vehicles washing and

maintenance of equipments.

Fabrication of offshore structures and ship building operate on a job basis. The main

operations envisaged at WIL are cutting, blasting, welding and painting.

Oxy-fuel welding (commonly called oxyacetylene welding, oxy welding, or gas

welding in the U.S.) and oxy-fuel cutting are processes that use fuel gases and oxygen to

weld and cut metals, respectively. In oxy-fuel cutting, a cutting torch heats the metal and

oxygen is trained on it and in result metal burns and then flows out of the cut (kerf) as an

oxide slag. The most commonly used fuel gases in the process are oxygen, Acetylene,

Liquefied Petroleum Gas (LPG), propane, natural gas and hydrogen gas. For the present

activity acetylene (non toxic and flammable) and oxygen will be used. The annual

requirement is 16000 oxygen cylinders, 8000 Acetylene cylinders and about 10000 LPG

cylinders for heating (as provided by WIL).

During abrasive blasting stream of abrasive material is forced against a surface under

high pressure to smooth a rough surface, roughen a smooth surface, shape a surface, or

remove surface contaminants. Although many abrasives used in blasting booths are not

hazardous in themselves, (steel shot and grit, cast iron, aluminum oxide [aka corundum],

garnet, plastic abrasive and glass bead), other abrasives (silica sand, copper slag, nickel

slag, and staurolite) have varying degrees of hazard (typically free silica or heavy

metals). Thus, Sand and copper slag blasting is not considered for this project.

Spray painting is done to protect metal against the corrosion and also to beautify an

object. Many paints, coatings, catalysts, sealers, hardeners, and solvents contain

hazardous chemicals. Exposure to chemicals can occur during mixing of the coating,

spraying the material, and grinding or sanding it. Symptoms of overexposure to

 

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hazardous chemicals include nausea, rashes, and long term illnesses like asthma, lung

cancer, and sensitization (becoming severely allergic to the paint). Apart from risk to

health fire hazard is another aspects to be looked at in the painting area. WIL will be

using only approved lead free paints and painting will mostly be carried out in enclosed

areas using specialized methods.

Apart from the main operation described above, operation of DG sets, vehicles plying on

the road to bring in and out the material and people are other activities with some

impacts.

Waste water generated from the project premises contains suspended and dissolved solid,

organic and in organic matter, nutrients such as nitrogen and phosphorous, paints, oil,

grease and pathogens. If wastewater is discharged without proper treatment, it would

have significant impact on surrounding environment. A sewage treatment plant is

proposed on the site to treat the effluent generated from the proposed project. The sewage

treatment plant would be designed to meet CPCB norms with respect to the discharge

limits. The treated effluent shall be used for landscaping and flushing.

Similar to the construction phase, the operation phase will also provide opportunities for

employment mostly in the skilled and semi skilled categories. Operation of the proposed

project will also require transportation facilities to the commuters to commute from a

nearby place to the project site and vice versa. This will enhance the income of the people

associated with transport sector. All these activities will need support services like food,

housing, school, medical facility etc. ultimately leading to improvement in quality of life

of local people. Indirectly, other service sectors also stand to benefit and impacts are

positive.

Adequate Environmental Management Plan is proposed to maintain the existing status of

the local environment. To arrest the dust pollution to be generated during the site-

levelling and reclamation activity is temporary.

 

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• All the internal roads have to be properly surfaced to reduce the fugitive dust due

to vehicular movement.

• Water sprinklers shall be used to control the fugitive dusts.

• Cleaner fuel will be provided to the labours to keep air pollution due to fuel

burning be restricted.

• Fossil fuel or timber burning will not be permitted in the premises.

• Diesel driven construction machineries shall be properly maintained to minimize

the exhaust emission and noise pollution.

Most of the offshore fabrication structures rely primarily on spraying methods for coating

application. Any activity involving paints, i.e., storage, mixing, coating and spraying may

lead to impacts on human health and environment. Thus, care would be taken to avoid

exposures to workers and spillage or leaks to the environment.

• Store waste paint and other related solvents in covered containers to prevent

evaporation to the atmosphere

• Use airless or high volume low pressure (HVLP) spray guns to reduce overspray.

Use high transfer efficiency coating techniques such as brushing and rolling to

reduce overspray shall be also explored.

• Proper ventilation facility and VOCs control provision will be made to avoid any

fire or explosion risk. Adequately fabricated spray booths is another option

which may be explored.

• Smoking and other such activity will be prohibited.

• Establish and adhere to “safe” wind directions and speeds for particular facilities.

There is provision of installation of Sewage Treatment Plant (STP) within the premises.

The waste water shall be treated in the STP and the treated water shall be reused in

landscaping. No waste water shall be released into the estuary. As far as solid/hazardous

wastes are concerned the steel scraps generated during the offshore fabrication structures

should be collected in scrap yard and dispose off periodically for recycling.

• Empty cans containing, paints, lubricants and oil must be disposed of daily in

designated waste disposal bins.

 

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• All hazardous waste would be transported to ankleshwar to the waste treatment

facility

• With regards to the disposal/treatment of waste, the project authorities shall

dispose /treat the waste as per the prevailing waste handling norms.

Trees are an effective mode of control of air pollution noise pollution, odour problem.

Leaves with their vast area in a tree crown, sorbs pollutants on their surface, thus

effectively reduce pollutant concentration in the ambient air. Often the adsorbed

pollutants are incorporated in the metabolic pathway and the air is purified. Plants grown

to function as pollution sink are collectively referred as greenbelts.

Odour can be reduced by developing green belt. Plants which counteract odour are

• Bushes with mild but active fragrance.

• Acacia sp: It is a type of bush with yellow coloured fragrant flowers. It does not

have rich canopy but very effective for counteracting smell. Its limitation is

seasonality and thorny nature.

• Melaleuca species: It has sweet fragrance and thin canopy in India.

• Junipers: They have excellent canopy and protection. Its limitation is site

specificity.

• Eucalyptus: It can be used as very good belt and can also be used as per odour

source. Its limitation is site specific and the urban neighbourhood.

• Hedges, Herbs (Tulsi, Turmeric etc.) can also be used for

counteracting odour.

• Vetiver : This plant is a king of perfumes for inactivating other odours. It

affects the nervous system and relieves fatigue. It is used as key species in

aromatherapy. Other than these, plants which are used to form green belt include

Bamboo, Pongamia pinnata, Neem and Casuarina etc.

Safety equipment for blasting operators will be:

 

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• Positive pressure blast hood or helmet - The hood or helmet includes a head

suspension system to allow the device to move with the operator's head, a view

window with replaceable lens or lens protection and an air feed hose.

• Grade D air supply - The air feed hose is typically attached to a grade D

pressurized air supply. Grade D air is mandated by OSHA to protect the worker

from hazardous gases. It includes a pressure regulator, air filtration and a carbon

monoxide alarm.

• Ear protection - ear muffs or ear plugs.

• Body protection - Body protection varies by application but usually consists of

gloves and overalls or a leather coat and chaps. Professionals would wear a

cordura/canvas blast suit.

• Blasting supervisors have the responsibility to ensure blasting operations and

abrasive materials management are conducted to reduce their environmental

impact.

• Those persons responsible for maintaining equipment and machinery required

for abrasive materials management need to be properly trained in those aspects

of equipment performance that effect emissions and productivity.

• Regular health check-ups would be taken up.

• Proper protection should be worn at all times, including to protect the eyes

against glare and flying sparks in welding, cutting and blasting areas.

• Workers shall avoid direct contact with these solvents and should not be using

solvents for cleaning paint from hands or skin. In lieu, use of water-based

cleansers for personal cleanup shall be encouraged.

• Implementation of Material Safety Data Sheet (MSDS) of the chemical will be

made necessary.

• Workers shall wear the appropriate personal protective equipment such as safety

glasses, a respirator (if medically qualified, properly fit-tested, and trained),

gloves or coveralls to protect themselves against its hazards.

• Workers shall be encouraged to work in shifts to avoid prolonged exposures.

• Additional protective measures should be taken when stripping lead chromate- or

zinc chromate-based paints.

 

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• Good housekeeping practise will be implemented.

• All the employees will be trained in the health, safety, and environmental aspects

related to their job.

• Well maintained first aid box will be provided at all strategic locations

• Safety appliances will be provided to the required workers.

• Where respirator use is required, the employer must establish a respiratory

protection program. The respiratory protection program addresses procedures for

properly selecting and using respirators in the workplace.

• Appropriate protective clothing and equipment (head coverings, gloves, and foot

covering) will be provided.

• Facilities to ensure that employees comply with basic hygiene practices that

serve to minimize exposure will be provided.

• Change rooms will be provided where employees must change out of their street

clothes to use protective clothing and equipment

• The change rooms will be equipped with separate storage facilities (e.g., lockers)

for protective clothing and equipment and for street clothes, and these facilities

must prevent contamination of street clothes

• Eating and drinking areas and surfaces shall be maintained as far as practicable

from any pollution.

For conservation of energy, following measures shall be adopted.

• Purchase of energy efficient appliances

• Promoting use of renewable energy, wherever possible and viable.

• Adjusting the settings and illumination levels to ensure minimum energy used

for desired comfort levels

• Use of compact fluorescent lamps and low voltage lighting.

• Sunscreen films on windows to reduce heating inside the office/admin buildings

• Promoting awareness on energy conservation within the premises

• Training staff on methods of energy conservation and to be vigilant to such

opportunities.

 

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Walchandnagar Industries Limited is a well established company with history of over 100 years.

In its present location in Maharashtra, WIL is particularly well known for the various schemes

initiated over many years for social upliftment of the society and improving the skill levels &

quality of life of the local populace. In keeping with those traditions, WIL has already

established contacts with the adjoining villages in the new location. All facilities and amenities

provided by other nearby industries have been reviewed. Discussions were held with the

Sarpanches on various possibilities of improving the life of the villagers and upgrading the skill

levels of the younger generation.

In consultation with them, the following areas have been identified for specific attention as part of

the corporate social responsibility scheme of WIL:

1. Providing improved health care system around the locality: This can be in the form of

arranging medical camps as per requirements, providing ambulance for nearby villagers as

required, providing mobile clinic facility etc. The local public health centre will be

augmented with necessary infrastructures in order to provide better local healthcare.

2. Skill Upgradation: WIL will take up necessary study for skill-mapping in the locality and

extend necessary help to develop relevant skills like providing scholarships to willing

students for suitable vocational training. The adequacy of local education system will also be

reviewed and necessary helps like providing modern amenities, tools for education like

computers & AV facilities can be sponsored. WIL will partner with Government in National

Health Programmes like Polio, TB, Malaria etc.

3. Upgradation of sanitation facilities and public utilities: Specific efforts will be taken for

improvement of sanitation facilities particularly in rainy season so as to avoid spread of

diseases like dysentery & other diseases linked with mosquito growth.

4. Repairs of existing internal roads and construction of new roads in nearby villages.

5. Relocation of temple near plot no.42.

6. Supporting afforestation or mangrove farming schemes of the Government.

 

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Keeping the environment and socio-economic conditions of the area in mind, the

following recommendations are made to maintain a healthy social as well as

environmental management approach for the proposed development.

• Plantation of vegetation of indigenous species should be undertaken in the

project area. It is also recommended that project authority should come forward

to contribute/support the state forest department financially for afforestation in

this part of Gujarat.

• This type of project will bring employment opportunity for the local villagers.

Priority shall be given to local villagers when it comes to employment. Besides,

a multi-specialty hospital, arrangement for drinking water facility in any of the

nearby village and establishment of a technical institution like ITI in this area are

recommended.

• Special scholarships for girl students up to 10th standard and donation of

computers to all the registered schools of Dahej area are also recommended.

Walchandnagar Industries is recommended to hire one computer teacher for each

school if needed.

• Upgradation of village and main roads should be taken up by the project

proponent. Avenue plantation should be taken up by all the industries around the

region which will not only increase the green cover as but also enhance the

aesthetic value.

******