Disposed

News Item Titled Odisha 9 Hospitalised After Suspected Gas Leak at Rourkela Steel Plant Appearing in the Times of India Dated 01 07 2024 v. Central Pollution Control Board

NGT7 Apr 2025Original Application No. 157/2024

Case brief

AI extract

What is this about?

Suo Moto application challenging a gas leak at Rourkela Steel Plant where nine workers were hospitalized. The Bench found the incident did not constitute a Major Accident under applicable Rules but directed the Respondent to strictly adhere to existing safety SOPs and SPCB recommendations to prevent recurrence.

What did the court decide?

Direction to Respondent No. 5 (Rourkela Steel Plant) to strictly adhere to its Standard Operating Practices (SOPs) and the recommendations made by the Odisha State Pollution Control Board.

News Item Titled Odisha 9 Hospitalised After Suspected… — Environment and Pollution | NGT (2025)

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Court No.1

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Item No.11

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BEFORE THE NATIONAL GREEN TRIBUNAL EASTERN ZONE BENCH, KOLKATA

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(THROUGH PHYSICAL HEARING WITH HYBRID MODE)

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Original Application No.157/2024/EZ (Earlier O.A. No.771/2024/PB)

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News Item titled “Odisha 9 hospitalised after suspected gas leak at Rourkela Steel Plant” appearing in The Times of India Dated 01.07.2024

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Applicant(s)

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Date of hearing: 07.04.2025

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CORAM: HON’BLE MR. JUSTICE B. AMIT STHALEKAR, JUDICIAL MEMBER HON’BLE DR. AFROZ AHMAD, EXPERT MEMBER

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For Applicant(s) : Suo Motu

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For Respondent(s) : Mr. Rajib Ray, Adv. for R-1 (in Virtual Mode),

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Ms. Papiya Banerjee Bihani, Adv. for R-2 (in Virtual Mode), Ms. Anamika Pandey, Adv. for R-3 (in Virtual Mode), Mr. Sanjay Rath, ASC for R-4 (in Virtual Mode),

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Mr. Kallol Basu, Adv. a/w Mr. Nilanjan Pal, Adv. for R-5 (in Virtual Mode)

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ORDER

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Additional affidavit dated 28.03.2025 has been filed on behalf of the

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Respondent No.3, Ministry of Environment, Forests and Climate Change (MoEF&CC); the same is taken on record.

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Heard learned Counsel for the parties.

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(The final order of this case shall be uploaded in the NGT Website

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by separate sheets of paper)

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B. Amit Sthalekar, JM

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..................................... Dr. Afroz Ahmad, EM

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April 07, 2025, Original Application No.157/2024/EZ (Earlier O.A. No.771/2024/PB) SKB

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Court No.1

Item No.11

BEFORE THE NATIONAL GREEN TRIBUNAL EASTERN ZONE BENCH, KOLKATA

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(THROUGH PHYSICAL HEARING WITH HYBRID MODE)

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Original Application No.157/2024/EZ

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(Earlier O.A. No.771/2024/PB)

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In the matter of:

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News Item titled “Odisha 9 hospitalised after suspected gas leak at Rourkela Steel Plant” appearing in The Times of India Dated 01.07.2024

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…. Applicant(s)

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Versus

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1. Central Pollution Control Board

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Through its Member Secretary, Parivesh Bhawan, East Arjun Nagar,

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Delhi – 110032;

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2. Odisha Pollution Control Board

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Through its Member Secretary, Paribesh Bhawan, A/118, Nilakantha Nagar, Unit-VIII, Bhubaneswar - 751012 Odisha;

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3. Ministry of Environment and Forest, Regional Office Integrated Regional Office, A/3, Chandersekharpur, Bhubaneswar – 751023;

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4. District Magistrate, Sundargarh

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Office of the Collector cum District Magistrate, Collectorate, Sundargarh, At/Po - Sundargarh, Dist. Sundargarh – 770001;

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5. Rourkela Steel Plant

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Through its Director/Executive Director, Sundargarh, Odisha

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…. Respondent(s)

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Date of hearing: 07.04.2025

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CORAM: HON’BLE MR. JUSTICE B. AMIT STHALEKAR, JUDICIAL MEMBER HON’BLE DR. AFROZ AHMAD, EXPERT MEMBER

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For Applicant(s) : Suo Motu

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For Respondent(s) : Mr. Rajib Ray, Adv. for R-1 (in Virtual Mode),

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Ms. Papiya Banerjee Bihani, Adv. for R-2 (in Virtual Mode), Ms. Anamika Pandey, Adv. for R-3 (in Virtual Mode), Mr. Sanjay Rath, ASC for R-4 (in Virtual Mode),

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Mr. Kallol Basu, Adv. a/w Mr. Nilanjan Pal, Adv. for R-5 (in Virtual Mode)

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ORDER

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The Original Application No.771/2024/PB was registered as suo motu O.A. by the New Delhi Bench of the Tribunal on the basis of a news item titled “Odisha 9 hospitalised after suspected gas leak at Rourkela Steel Plant” published in The Times of India dated 01.07.2024.

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The news article mentions hospitalization of 9 (nine) people following a suspected gas leak incident at Rourkela Steel Plant in Odisha. It is stated that 9 (nine) persons, including three officials and six contractual employees felt unwell while working in the blast furnace no. 5 after coming in contact with some gas. It is alleged that the leak was reported in a blast furnace of the Plant.

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Thereafter, the said Original Application was transferred by the New Delhi Bench of the Tribunal vide its order dated 09.07.2024 to the Eastern Bench of the Tribunal and the case has now been renumbered as Original Application No.157/2024/EZ.

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The Respondent No.3, Ministry of Environment, Forests and Climate Change, has filed affidavit dated 31.08.2024 and reference has made to Rule 2 of the Manufacture, Storage and Import of Hazardous Chemicals Rules, 1989 (‘MSIHC Rules, 1989’ for short) which defines Major Accident to mean – ‘an accident involving loss of life inside or outside the installation, or ten or more injures inside and/or one or more injuries outside or release of toxic chemicals or explosion or fire or spillage of hazardous chemicals resulting in on-site or off-site emergencies or damage to equipment

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leading to stoppage of process or adverse effects to the environment’.

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The Respondent No.2, Odisha State Pollution Control Board, has filed affidavit dated 06.09.2024 bringing on record the Preliminary Investigation Report of an inspection of the site in question carried out on 01.07.2024. The Preliminary Investigation Report reads as under:-

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“Preliminary investigation Report on Incidental Exposure of Carbon Monoxide (CO) Blast Furnace-V of M/S. Rourkela Steel Plant (SAIL), Rourkela Dist: Sundargarh, Odisha

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On receipt of information about incident through news and Member Secretary, SPCB, Odisha and Er. B. K. Behera, CEE, SPCB, Odisha, Bhubaneswar, Blast Furnace-V of Rourkela Steel Plant was inspected on dtd.01.07.2024 by RO, SPCB, Odisha, Rourkela with Er. C. S. Chauhan, DEE and Er. B. K. Bhoi, DEE in connection with exposure of Carbon Monoxide (CO) gas in scrubber & clarifier area (near U-Seal-1) of Blast Furnace-V. Sri Sumeet Kumar, GM (Blast Furnace), Mr. P.C Dash, GM-I/C (Env. Engineering Department), Mr. V. V. R Murty, GM (Env. Engg. Dept.) & others of RSP were present during inspection.

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Observations:

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1. By the time we reach at the incident site, affected person were shifted to the Ispat General Hospital (IGH). Area (Useal-1 of Blast Furnace-5) where leakage was occurred has been cordoned off by the RSP.

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2. Leakage was completely stopped by the RSP. We didn’t find any CO leakage from the area during our visit. Which was also ensured through the CO gas detectors both by online and portable.

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3. It was observed from the Continuous Ambient Air Quality Monitoring Stations (CAAQMS) installed by the RSP at four (04) location inside plant premises that concentration of Carbon Monoxide (CO) in the ambient area at respective

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locations does not exceeds the prescribed standards of the Board. It reflects that impact of leakage was local only.

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4. The matter was discussed with the Sri Sumeet Kumar, GM (Blast Furnace) and others at the site. Following information has been furnished by the RSP (SAIL) authority:

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At around 10:40 AM on dt.01.07.2024, employees working in scrubber & clarifier area of BF-5 found 3 labour of M/s TPL lying unconscious on the road near U- Seal - 1. Immediately ambulance was called on the spot by the area I/C and the above 3 workmen were taken to first aid and then admitted to the Ispat General Hospital (IGH) for treatment.

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Gas leakage was observed from the drain of nearby U- Seal-1 and the U-Seal was immediately isolated.

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6 workmen who rescued the affected were also taken to first aid and 5 of them were admitted in IGH as a precautionary measure. 1 lady contractual employee was released after being administered the first aid at OHSC.

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Cause of the gas leakage is under investigation and details will be shared by the SAIL authority after a thorough enquiry.

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Details of the injured person

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*SI.* *No.*	*Name of the* *injuredperson*	*Designation*	*Age*	*Status*
1.	Sri Jairam Bank	Sr. Mgr, BF(O)	36	Bed-13, IGH
2.	Sri P. K. Sahu	MOMT, BF	52	Bed-14, IGH
3.	Sri Dikhisyam Das	MOMT, BF	36	Bed-11, IGH
4.	Sri Raju Ku. Maiti	Contractual	38	Bed-12, IGH
5.	Sri Pradip Kujur	Employees, M/S TPL	30	Bed-3 (B), IGH
6.	Sri Santanu Nayak		33	Bed-7, IGH
7	Sri Suraj Chhatri		26	Bed-4, IGH
8.	Smt. Laxmi Singh	Contractual	34	Bed-10, IGH
9.	Smt. Pana Soren	Employees, M/s S K Gouda	39	Released after first aid

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All the eight persons admitted fin IGH are in stable

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condition and will be released shortly.

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Recommendation

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1. RSP shall ensure to deploy only trained workers in CO emission prone areas and they must have portable CO detector.

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2. Industry shall upgrade existing alarm systems in the U- Seal areas.

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3. Industry shall ensure proper housekeeping in Gas Cleaning Plant (GCP) area.

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4. Industry shall clear the siltation in the drains in GCP area.

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Note:

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By the time report is prepared, it is informed by the RSP authority that all affected persons have been released from the Ispat General Hospital (IGH).”

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The Respondent No.4, Collector & District Magistrate, Sundargarh, has filed affidavit dated 20.09.2024 stating that as per the site Inspection Report and information received from the DGM (HR) IR, R&GA, Steel Authority of India Ltd., Rourkela vide letter dated 18.09.2024 on the gas leakage, it has been informed that there have been no causalities so far as affected persons are concerned and on 03.07.2024 all of them have reported for duty and to avoid any untoward situation in future, additional safety protocols have been initiated by the Rourkela Steel Plant Limited.

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The Respondent No.1, Central Pollution Control Board, has filed affidavit dated 26.11.2024. Along with this affidavit, a copy of Manufacture, Storage and Import of Hazardous Chemicals Rules, 1989 has also been filed.

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The Respondent No.5, Rourkela Steel Plant, Sundargarh, has filed affidavit dated 06.01.2025 giving details of the workmen who were affected due to the gas leakage whose names are as under:-

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Sl. No.	Name of the injured person	Designation	Age
1.	Sri Jayram Barik	Sr. Manager, Blast Furnace (O)	36
2.	Sri Pradeep Kumar Sahoo	Sr. Operative, Blast Furnace	52
3.	Sri Dukshishyam Dash	Operative Blast Furnace	36
4.	Sri RajuKU.Maity	Contractual	38
5.	Sri PradeepKujur	Employees, M/s	30
6.	SriSantanuNayak	Tata Projects Ltd.	33
7.	SriSuraj Chhatri		26
8.	Smt.LaxmiSingh	Contractual	34
9.	Smt. Pano Soren	Employees, M/s SKGouda	39

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It is stated that on 01.07.2024 at around 10:40 A.M., employees were working in the Gas Cleaning Plant of Blast Furnace-5 (Scrubber & Clarifier Area) and suddenly, it was found that 3 (three) contractual employees of M/s Tata Projects Ltd. were lying unconscious on the nearby road; immediately ambulance was called on the spot and the 03 workmen were taken to the Occupational Health & Service Center (OHSC) inside the Plant premises for first aid and thereafter, they were admitted to the Ispat General Hospital, Rourkela for further treatment. It is also stated that 6 (six) workmen who were involved in rescuing the said 3 (three) workmen, were also affected and taken to the Occupational Health & Service Center (OHSC); out of the said 6 (six) workmen 5 (five) workmen were taken to Ispat General Hospital for treatment as a precautionary measure and 1 (one) female contractual employee was released after being provided first aid at Plant OHSC; thus, total 8 (eight) workmen were admitted in the Ispat General Hospital and out of the 8 (eight) workmen, one Shri Jairam Barik

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was discharged from the said hospital on the same day in the evening and the rest workmen were discharged from the hospital on the very next day. It is further stated that all the workmen reported for duty on 03.07.2024.

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It is stated that after adequate examination, Blast Furnace Gas leakage was observed from the drain of nearby U-Seal of Blast Furnace Gas Line and the U-Seal was immediately isolated and measures were put in place to prevent incidents of gas leak, keeping in view the ‘Precautionary Principle’ as required in environmental matters. It is also stated that at the time of inspection by the State Pollution Control Board, it was observed that leakage was completely stopped by the Respondent No.5 and the inspecting team did not find any Carbon Monoxide leakage from the area during their visit. It is further stated that the recommendations in the Inspection Report have been fully complied and reply to that effect has also been communicated by the General Manager, Environmental Engineering Department of the Respondent No.5 through his letter dated 15.07.2024 and an Action Taken Report has also been filed before the Odisha State Pollution Control Board. It is, however, stated that the State Pollution Control Board further inspected the Plant site on 27.08.2024 and in the Inspection Report, it has been stated that the Respondent No.5, Plant, has fully complied with the directions of the State Pollution Control Board.

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The measures taken by the Respondent No.5 for avoiding reoccurrence of such incident has been outlined in paragraph-11 of the affidavit which read as under:-

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“a. Locking arrangement provided in spindle of the flushing valve of all the 03 (Three) U-Seals to prevent accidental opening of the valve.

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b. In the vicinity of each of the 03 (Three) U-seals, Carbon Monoxide (CO) Monitors with alarms have already been installed. In addition, 03 (Three) new Online Carbon Monoxide (CO) Monitors have been installed whose feedback is connected to Human Machine Interface (HMI) Operator Panel with an Audio Alarm at Main Emergency Control Room to ensure continuous online monitoring.

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c. In case of high CO concentration, the online CO monitor will activate the Public Announcement (PA) wherein emergency announcement in both languages being Odia and Hindi language has been provided to evacuate the area.

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d. Emergency contact numbers, including OHSC, Ambulance, Safety and the plant control number have been displayed at all U-seals.

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e. Closed Circuit television Cameras installed near all the U- seals of BF-5 for better monitoring.

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f. Barbed Wire barricading has been provided at all the 03 (Three) U-Seals to restrict unauthorized entry into the area.”

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It is stated that Standard Safety Protocols have been formulated/adopted by the Respondent No.5 in connection with handling of fuel gases and operation of blast furnaces and 23 Standard Operating Practices (SOP) have already been installed for Blast Furnace-5 Operation which includes Operation of various units of Blast Furnace-5, Shutdown, Start-ups, handling of Hotmetal and Slag, and Water Sealing & Breaking in U-Seals.

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The Respondent No.2, Odisha State Pollution Control Board has filed further affidavit dated 28.01.2025 bringing on record an

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Investigation Report of the incident which occurred on 01.07.2024 which reads as under:-

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“Committee Report

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A committee was constituted with reference No. ED(W)/PSO/247 dated 01.07.2024 to investigate gas leakage incident took place at BF-V U-Seal area comprising of the following members:

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1. Sri Kartikeya Behera, CGM (NPM & SPP)

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2. Sri Abakasa Behera, GM, Safety Engineering Department

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3. Sri B.P. Pandey, DGM, EMD

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On 01.07.2024 at around 10.37 AM it was reported to fire service department that few employees and contractual employees have gas exposure near BF V clarifier road adjacent to TRT, similarly a call was made to OHSC for deputing ambulance for emergency evacuation of affected persons by Sri R.S. Kaushal, GM BF. Persons working nearby tried to rescue the affected persons from the area and in due course of evacuation they were also exposed to gas. Fire service personnel administered artificial resuscitation to two affected persons of M/s TPL at site at around 11.00 AM. All the nine affected persons were sent to OHSC and thereafter eight persons shifted to IGH for further medical treatment. By 2PM, 6 persons were declared fit and shifted to ward at 5 PM, remaining two persons declared fit and shifted to ward on 02.07.2024 at 8 AM. All persons discharged from IGH on same day.

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Committee visited the site on 01.07.2024 and interested with operation & maintenance crew of the Blast Furnace-V and Fire Services Department.

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Sequence of events leading to incident:

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a) There are three BFG water seals in BF-5 area. Water seal no.1 drain valve repair job was scheduled to be

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under taken during planned shutdown of BF-V in 2^nd half.

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b) Housekeeping job was being carried out near thickener area.

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c) Sri J Barik Sr. Manager received information that around 4 persons are feeling uneasy and laid down probably due to poisonous gas exposure at 10.40 a.m.

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d) Mr. Barik arrived at site with his two non-executive colleagues (Sri P K Sahoo and Sri Dukhishyam Das) and started rescuing the affected persons.

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e) Two more contract employees were working in nearby area also helped to rescue the victims.

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f) Fire Brigade team and ambulance arrived at site and shifted the victims to OHSC and thereafter IGH.

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g) At around 10.40 AM Sri Sushant Swain of GCP operation received a call from Sri Ganesh Munda that one person found to be sitting and gradually laid down on the floor near flare stack area.

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h) Sri Swain went to LD booster station area near the ramp and observed that gas is gushing out from the BFG water seal no.1 drain seal.

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i) He arrived at the spot donning OBA (Oxygen Breathing Apparatus) and closed the drain valve of BF gas U seal no.1 and after some time the overflow was maintained. The area was cordoned off and barricaded. The gas leakage arrested.

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Root Cause of the incident:

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Possible causes of the incident:

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1. BFG Water seal no.1 drain seal might have blown away due to pressure fluctuation in the BF grid. Committee studied the BFG stove line pressure transmitter (nearest to water seal) graph and maximum pressure recorded in the shift was 0.14 Kg/cm2 which is within norm and the possibility of seal breakage is ruled out (as water seal designed to

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sustain maximum pressure of 0.27 Kg/cm2: committee measured the sealing height).

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2. There was plan to shut down BF-V for four hours for tuyers replacement during which waster seal no.1, 2 & 3 were to be raised. To ensure proper functioning of isolation valves of the U seals, inspection/servicing/checking of the valves might have been carried out, in the process of checking drain valve of U seal no.1 (NB150) the drain valve might not have been fully closed leading to leakage of water. This lead to breakage of drain seal which resulted gushing out of BF gas hence exposure of gas.

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Suggested remedial measures to prevent re-

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occurrence:

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1. Water seal overflow to be ensured and recorded in every shift.

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2. Level switches with audio visual alarm in control room to be installed in all 3 U seals to alert the operator whenever the water level is getting low to take corrective action.

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3. NB150 drain valve to be kept in blank condition in normal operation, De-Blanking and flushing of the water seal to be carried out under direct supervision with PTW.

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4. On line CO detector near the vicinity of all water seals to be installed with audio visual alarm at control room and indication in POC.

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Fixing Responsibility for the incident:

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1. Direct supervision and coordination between mechanical and operation could have avoided this incident.

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2. Inspection and maintenance of U-seal & gas line to be carried out under direct supervision by respective agencies. The concerned mechanical executive handling outsourced agency M/s TPL for the U-seal maintenance is responsible for the incident.

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Measure to be taken to stop re-occurrence of the

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incident:

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1. All the water seal areas to be monitored through CCTV.

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2. Drain seal size to be reduced from NB300 to NB150 which will reduce gas flow to 1/4^th in case of breakage of water seal.

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3. Adequate multilingual signage, DO’s & Don’ts to be provided near U seal area for alerting the employees.

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4. Wind sock to be provided at prominent locations.

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5. CABA (compressed air breathing apparatus) set and OBA (Oxygen breathing apparatus) to be stored at ground floor to reduce the time.

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6. Fencing around the U-Seal area to be done with Entry Gates.

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7. Periodic Calibration of Online CO Monitors to be done on monthly basis and record to be maintained.

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8. BFG to Stove gas line Pressure relief logic set pints to be suitably reduced to avoid pressure surge in water seal due to process upset.”

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Under the Heading – Root Cause of the Incident, the possible causes of the incident have been outlined namely that the BFG Water seal no.1 drain seal might have blown away due to pressure fluctuation in the Blast Furnace Grid; the Committee studied the BFG stove line pressure transmitter (nearest to water seal) graph and maximum pressure recorded in the shift was 0.14 Kg/cm2 which is within the norms and possibility of seal breakage is ruled out; there was plan to shut down BF-V (Blast Furncae-5) for four hours for tuyers replacement during which the water seal nos.1, 2 & 3 were to be raised; to ensure proper functioning of isolation valves of the U-Seals, inspection/servicing/checking of the valves might have been carried out and in the process the drain valve might not have been fully closed leading to leakage of water which

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led to breakage of drain seal which resulted in the same leaking out of Blast Furnace Gas hence exposure of gas.

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Thereafter, remedial measures have been suggested to prevent reoccurrence of such incidence in future but it has held the concerned mechanical executive handling outsourced agency, M/s Tata Projects Ltd., as responsible for the U-Seal maintenance resulting in the incident.

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The Respondent No.3, Ministry of Environment, Forests and Climate Change, has filed further affidavit dated 28.03.2025 and it is stated that Directorate of Factories & Boilers, Odisha vide its letter dated 30.01.2025 has stated that accident in question does not come within the definition of “Major Accident” as per Rule 2 (j) of the Manufacture, Storage and Import of Hazardous Chemicals Rules, 1989 and does not attract the provisions of Rule 5 of the Rules 1989.

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In view of the facts emerging from the various affidavits and documents on record including the Inspection Reports, we find that the incident in question has been certified by the Directorate of Factories & Boilers, Odisha, as not falling within the definition of a “Major Accident” as per Rule 2 (j) of the Manufacture, Storage and Import of Hazardous Chemicals Rules, 1989. However, care still needs to be taken by the Respondent No.5 to ensure that there is no re-occurrence of a similar situation in future.

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We, therefore, dispose of this Original Application with a direction to the Respondent No.5 to ensure that the Standard Operating Practices (SOP) outlined by it in its affidavit as well as the suggestions and recommendations made by the Odisha State Pollution Control Board are strictly adhered to in future.

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I.As. if any, stand disposed of accordingly.

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There shall be no order as to costs.

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B. Amit Sthalekar, JM

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Dr. Afroz Ahmad, EM

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April 07, 2025, Original Application No.157/2024/EZ (Earlier O.A. No.771/2024/PB) MN

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News Item Titled Odisha 9 Hospitalised After Suspected Gas Leak at Rourkela Steel Plant Appearing in the Times of India Dated 01 07 2024 v. Central Pollution Control Board

Case brief

What is this about?

What did the court decide?

News Item Titled Odisha 9 Hospitalised After Suspected Gas Leak at Rourkela Steel Plant Appearing in the Times of India Dated 01 07 2024 v. Central Pollution Control Board

Case brief

What is this about?

What did the court decide?

What the court decided

A compact analysis

Issues for consideration

Statutes considered

Parties & counsel

Coram

Case details

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