Msil Intro

1. INTRODUCTION

1.1 Legal Requirement

The preparation and practice of the On-Site Emergency Plan (OEP), with detailed disaster control measures and keep it up-to-date is the legal responsibility of the occupier of the factory as per Section 41-B (4) of the Factories Act, 1948 and Rule 70(L) of the Haryana Factories Rules, 1952 and Rule 13 of the Manufacture, Storage and Import of Hazardous Chemicals (MSIHC) Rules, 1989. Maruti Suzuki India Limited (MSIL), Gurgaon is handling Liquefied Petroleum Gas (LPG) for the process. The handling capacity of LPG is 60 MT, stored in the three above ground storage tanks having capacity of each 20 MT. In accordance with the MSIHC Rules, 1989 (amended in 1994) the threshold quantity of LPG has been laid down as 32 MT of LPG for preparation of the On-site Emergency Plan by the Occupier.

1.2 Basis of the Plan

The plan was initially developed in September 2003 covering the major probable hazards envisaged under the Risk Analysis Study carried in 2003. Now, the Plan is modified taking in accordance with the following:

The observations made by the Factory Inspectorate, Haryana Recommendations of the EHS Risk Assessment Study carried by the National Safety

Council (NSC), Mumbai in Aug. 2005 Quantitative Risk Assessment carried out by NSC in Sept 2006. Schedule XI of Rule 13(1) of the MSIHC Rules, 1989. Elements of the On-site Emergency Plan under the APELL (Awareness and Preparedness

for Emergencies at Local Level) Handbook developed by the United Nations Environment Programme (UNEP).

1.3 Purpose and Scope

The purpose of formulating an emergency plan is to develop a state of readiness, which will allow for a prompt and orderly response to an emergency and to comply with the statutory obligations as stated above. This plan is structured around four major objectives:

Understanding the type and extent of a potential emergency (risk/exposures);

Establishing a high order of preparedness (equipment, personnel) and commensurate with the risk;

Ensuring an orderly and timely decision-making and response process (notification, standard operating procedures), and

Providing an incident management organisation with clear missions and lines of authority (Incident Command System, field supervision, unified command).

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On-Site Emergency Management Plan & Disaster Control Measures of Maruti Suzuki India Ltd., Gurgaon 1.1

This Plan is targeted to –

Contain the effect of the incident Minimise casualties and prevent further injuries Quick relief and rescue operation without delay Speed up restoration of normalcy Ensure that each member of the emergency operation including response team and

employees are aware of his/her precise role in emergency

1.4 About the Factory

1.4.1 Location

Maruti Suzuki India Limited (MSIL) is situated on the old Gurgaon-Delhi Road, at distance of about 7 km from Gurgaon Bus Stand. The factory is about 25 km. from the South New Delhi.

1.4.2 Profile of MSIL

The principal activities being carried out by MSIL is the manufacturing of Automobiles. The factory is registered under the factories registration No. GGN/M-165/6967.

MSIL, a subsidiary of Suzuki Motor Corporation of Japan, is India’s largest automobile manufacturing company. It was setup in collaboration between Government of India and Suzuki Motor Corporation of Japan to provide affordable, fuel efficient and environment friendly compact cars. MSIL is known for introducing an open work culture, progressive concepts like Kaizen, 5S & 3G and Japanese participative management.

MSIL factory is spread over a sprawling 293 acres of land with 3 fully-integrated production facilities. The production of the vehicles was started in 1983. The factory employs about 4000 employees and about 5000 contract employs in the manufacturing process and other operations. The shift wise no. of personnel will be as per shift time applicable. The information about the factory along with number of personnel available at any given time in the factory is given in Annexure-1.

1.4.3 Brief Process Description

The factory manufactures automobiles. The manufacturing activities include press and blanking, welding, painting and assembly operations.

Sheets are received in Press & Blanking Line. The roll of sheet is cut in smaller sheets. These sheets are fed in presses and various components are formed by using different dies. The sheet metal components are welded with welding jig and gun robots to make white body shell in Weld Shop and completed body goes to Paint Shop. In Paint Shop body shells coming from the Weld Shop are painted after washing and painted body sent to Assembly Shop. In Assembly Shop, vehicles are assembled, tested, inspected and release for despatch. The activities also include captive power generation using gas turbine.

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Press Shop & Blanking

Line

Weld Shop

PaintShop

AssemblyShop

Vehicle Inspection

Shop

Engine Assembly

Shop

Machine Shop


Process Flow Diagram of Vehicle Production

A variety of materials are being handled in the factory. However, the hazardous chemicals such as Liquefied Petroleum Gas (LPG), Petrol, HSD, CNG and Thinner & Paints are being handled which may owe to the risk if not handled properly.

The factory layout showing various sections, storages, offices, etc. is included as Annexure-2.

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2. EMERGENCY ORGANISATION AND DUTIES

The plan takes into account the transition from normal operations to emergency operations and the delegation of authority from operations personnel to emergency response personnel. For this purpose, it identifies an emergency response organisation with appropriate lines of authority and the way response management would come into action. It also identifies position, mission, duties, and reporting relationships of each responder.

2.1 Concept of Emergency Response Operation

In an emergency, information must be communicated quickly and accurately throughout the factory. The purpose is to establish an effective emergency communication network and a procedure for the prompt notification of individuals and agencies involved in an emergency response.

The section must identify means for 24-hour notification of first responders and officials who can provide direction and control to the response effort and who can authorise evacuation. To prevent the system breakdown, an "alternate" person should be designated for each key position of designated responsibility. A notification guide should also include a list of alternate personnel for emergency response and their telephone numbers (Mobile, Office and Residence numbers).

The notification procedure may include flow-charts and checklists indicating who should be involved, who has the responsibility to notify these individuals, how the notification is accomplished and the use of "fan out" (a call to one person/agency who in turn calls one or more key individuals during a major emergency). These telephone numbers and checklists may be posted in critical areas for ready use or distributed as pocket cards.

The Emergency Response Organisation is deployed even during those periods when the Plant is operating in shifts with reduced personnel. Therefore, the responsibility of co-ordinating the emergency response action lies with the Shift In-charge until he is relieved by higher-ranking personnel, such as Asstt. Manager/Plant Head/Sectional Head when he arrives at the incident site.

2.2 Emergency Organisation

Command and control of an emergency condition encompasses the key management functions necessary to ensure the health and safety of employees, as well as public living in the vicinity. In addition, the implementation of an Emergency Response Plan relies on a number of response functions, which deal with different aspects of emergency, with the most important ones being:

Communication and Co-ordination Fire and Rescue (Emergency Mitigation) Emergency Control Team at Incident Site Medical Services Security Administration (Logistics & Welfare) Liaison with external agencies

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2.2.1 EMERGENCY MANAGEMENT ORGANISATION CHART AT MARUTI SUZUKI INDIA LIMITED, GURGAON

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Site Controller MEO (PROD)

OrDVM-CEP

Incident ControllerDivisional Head/

Deptt. / Sec . Manager/Shift In-charge

Emergency Support & Technical team

MEO- ADMIN EO-PE DVM – Finance DVM – PRDS DDVM – Plant HR DDVM- PLG-1 DDVM- PLG-2 DDVM- PLG-3 DDVM- PMNT DDVM-PCON DDVM- FCGE DPM– Safety & Welfare DPM- EM4 Chief Safety Officer

Medical TeamLeader – CMO

Maintenance TeamLeader – Deptt./ Sectional Head

MP1/MP2/MPC/EM1/EM2/EM3/CVL

Security & Vigilance Team

Leader – DPM (Vigilance)

MD

Fire & Rescue TeamLeader – Fire Officer

.

Facilities Team Transport – Asstt Mgr

(Transport) Communication – Asstt Mgr Food – Dy Mgr Head Count - -DPM( EMR) – (Overall ) -DPM(SHOP-EMPLOYEES & CONTRACTORS) Rehabilitation- Welfare Officer

MEO& DIRs


2.2.2 Response Level Matrix during Emergency

SlNo.

Location/Area Incident Controller Gen Shift andA & B Shifts

Alternate Shift C

1. Plant – 1 Div. Head Dept. Head Shift In-charge 2. Plant – 2 Div. Head Dept. Head Shift In-charge 3. Plant – 3 Div. Head Dept. Head Shift In-charge 4. FCGE Div. Head Dept. Head Shift In-charge 5. Utility Div. Head Dept. Head Shift In-charge6. Mezzanine – I Dept. Head (Vigilance) Asstt Mgr. ( VGL ) Not Applicable

7. Mezzanine – II Dept. Head ( MSD) Manager ( MSD) – Safety Coordinator

Not Applicable

8. R & D Bldg. Div. Head-ERD1 Div. Head-ERD3 Not Applicable9. Spares Div. Head Dept. Head Not Applicable10. Sales & Despatch Dept. Head Sec Head Not Applicable

In accordance with the organisation structure, the personnel in-charge of each of the above functions responds to the Site Controller (SC), who is overall in-charge of the Plant. Each function is staffed with a team, the size and composition of the team depends on the task required to be carried out during the emergency and the size of facility. These teams then operate according to the instructions provided by the SC and within the purview of prewritten guidelines to accomplish their task. Some of these teams mainly operate from the Emergency Control Centre (ECC) and others would operate in the field or in other part of the Plant.

2.3 Designated emergency key personnel in-charge and their alternates

Sl.No.

Designated Persons Main Alternate Duty Location

1 Site Controller (SC) MEO (Production) / Factory Manager

DVM (CEP) ECC

2 Incident Controller (IC) As per above Matrix At incident site3. Fire & Rescue Team Fire Officer Fire Supervisor At Incident site4. Security & Vigilance

TeamDept. Manager (VGL)

Asstt Mgr (VGL) ECC

5. Maintenance Team Deptt./Sectional Head

Asstt. Manager At Incident site

6. Medical Team CMO-1 CMO-2 Plant Dispensary7. Administrative Team Alternate8. Liaison with Media MEO (ADMIN) DDVM(PHR) ECC

9. Head Count DPM (EMR) Asstt/ Dy Mgr (EMR) Assembly Point

10. Transport Asstt Mgr. (TPT) Asstt -Tpt ECC

11. Communication Sup (Communication)

Asstt- Communication Telephone Exchange

12. Food supply Manager (Canteen) Supervisor (Canteen) Canteen

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2.4 Functions of Designated Persons during Emergency

2.4.1 Site Controller (SC)

The Site Controller (SC) has an overall responsibility for directing operations and calling outside help. Mr. M.M. Singh, MEO (Production) assumes the role of SC. Depending on the location of the emergency site and the prevailing wind direction, the SC will decide and use one of the two Emergency Control Centers, one at Fire Station and another near JV Gate for handling and controlling the emergency. He will then proceed to that Emergency Control Centre and take overall control of the emergency. Specific responsibilities/duties of the SC are as under:

1. After assuming the position as SC, he would get the information from the Incident Controller (IC) and take overall control of the emergency.

2. Decide and declare (if not already done) whether major emergency exists or likely requiring the emergency services.

3. Decide and declare the location of ECC and Assembly point after consulting IC / Fire incharge / Safety Officers.

4. Take charge of ECC.5. Ensure that the key personnel are apprised and discussed for further actions. 6. Exercise direct operational control of those parts of the factory, which are outside the affected

area.7. Continually review and assess existing and possible developments to determine the most

probable course of events and effective methods to deal with them.8. Direct a safe shut down and evacuation of plants, if required, in consultation with the IC and

key personnel.9. Ensure that casualties are receiving adequate attention. 10. Arrange for hospitalisation of victims and additional help if required. 11. Ensure that families / relatives of affected persons are informed.12. If necessary, inform and liaise with Fire Services, Police Services, District Emergency

Authorities and Officials of Directorate of Industrial Safety and Health, Govt. of Haryana.13. Ensure accounting of personnel and collate the actual attendance with the master list of

persons including contractors and visitors. 14. Arrange for the rescue of missing ones.15. Arrange control of traffic movement within the Plant.16. Arrange for the safe removal of vehicles loaded with flammable or dangerous substances from

the incident site.17. Arrange maintenance of chronological record of the events.18. Decide whether off site emergency exists or is likely to take place. If off site emergency exists-

18.1 Arrange to alert / evacuate the public living in the vicinity of the Plant.18.2 Call out outside emergency services. 18.3 Inform district emergency authorities.18.4 Coordinate with district emergency authorities to mitigate the consequences

outside the factory.18.5 Coordinate with district emergency authorities for evacuation, shelter, rescue

and rehabilitation of general public in the vicinity of affected area.19. Issue authorised statements to the press or the media in consultation with media contact

person.

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20. Inform company senior officials.21. Declare cessation / termination of emergency after having full control on emergency event.22. Control rehabilitation of affected area after the emergency is over.23. In case of Strike by the Plant Personnel, identify critical areas of the Plant in advance. If

emergency occurs during the strike, following arrangements are required to be made to meet the crisis

Keep List of Technical & Administrative Records needed to run the factory in an emergency and train the team.

Keep the record of Personnel (Non-executive) likely to be available during the strike and keep the same in safe custody.

Identify alternate arrangements for meeting any emergency in the factory, i.e. by mutual aid with other factories, etc.

2.4.2 Incident Controller (IC)

The IC operates from the nearest accident site. As per the response level matrix as indicated above assumes the role of IC. For silent hours, i.e. B and C shifts or on holidays the senior most available for that shift would work as IC until the arrival of the seniors. The responsibilities of the IC are as under:1. Take charge of the scene of emergency as IC2. As soon as he assumes the position as IC, he should assess the scale of emergency.3. Discussed and decide with the Site Controller for continuation of plant operations or

shutdown.4. If shutdown requires - activate the on-site emergency plan.5. Inform the ECC and SC and appraise the situation from time to time.6. Ensure that key personnel have been called in7. Search for trapped persons or casualties, if any.8. Initiate rescue operations until the rescue team arrives.9. Evacuate the non-essential persons and direct them to report at the Assembly Point. 10. Depute responsible person/s for head counts at the assembly point decided.11. Set up communication network with the Emergency Control Centre (ECC-1 or ECC-2, as

the case may be), using Intercom / walkie-talkie / Mobile phones.12. Ensure that the outside emergency services have been called in, if required.

13. Direct all operations within the affected area with following priorities –i) Secure safety of personnel, giving priority to saving life and preventing further injury.ii) Minimise damage to plant, property and the environment.iii) Minimise loss of material.iv) Advice and inform as required by the emergency responders, i.e. Fire and Security

personnel or emergency services.14. Keep SC informed of the developments.15. Preserve evidences, which would be necessary for subsequent investigation to find out the

immediate and underlying causes of the emergency and for concluding preventive measures.

16. Assess whether the leakage and/or fire can be stopped or controlled and consult SC.

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2.5 Other Functions and Personnel

Following functions with teams are required to be carried out in order to effectively tackle the emergency.(1) Fire and Rescue Team & Fire volunteers(2) Security & Vigilance Team(3) Medical Team (4) Facility Team(5) Maintenance Team(6) Co-ordination through Emergency Control Center (ECC)(7) Natural Calamities Crisis Control (8) Liaison with external agencies (9) Assembly Points and Head count

2.5.1 Fire and Rescue Team

This is the most important function and hence all care is taken to ensure that the team members have sufficient knowledge and skill in fire fighting and also to ensure that they have been trained and tested periodically.

Dy. Manager - Fire is the in-charge for the operation and handles this function in consultation with the IC.

Team

The fire and rescue team would typically consist of personnel from fire department. This team would be assisted by security personnel for handling the injured one and also for rescue operation. List of team members is given in Annexure - 3. The rescue coordinators will be safety coordinators as per the list given in Annexure - 4.

Functions

A) Team Leader

1. Rush to the spot of emergency on receipt of message2. Assess the situation and co-ordinate rescue operation such as evacuation of affected

personnel, and isolation of affected area.3. Decide beforehand proper use of fire fighting equipment.4. Ensure availability of PPE and their safe use by the team members5. Check the wind direction and advise the fire fighting operation accordingly. 6. Ensure that sufficient numbers of trained fire fighting persons are always available on

site.7. If required arrange to contact and call other trained fire persons.8. Discus with IC & SC for wind direction to decide ECC.9. Assess the situation and in consultation with the IC and SC call for external help. 10. Take part in the fire fighting if situation so demands

11. Keep / arrange liaison with members of Mutual Aid and establishments such as Industries as well as with Haryana Fire services for additional help

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B) Team members

1. Be available at their work stations.2. Note down the fire call details in the prescribed format.3. Quickly respond and rush to the scene of emergency.4. Report their team leader / senior person at site.5. Know, understand and follow safe use of fire fighting equipment.6. Use fire-fighting equipment properly.7. Use appropriate PPE.8. First priority would be given to save lives by rescuing people.

2.5.2 Security & Vigilance Team (Traffic Control)

It is very important that during the emergency, the movement of persons within the factory is controlled effectively, non-essential persons and vehicles are guided to pre-determined locations and only essential persons and vehicles are allowed to tackle the emergency. To prevent access by the public into an area used by the fire service and other services for support activities is another responsibility of this team. List of team members is given in Annexure - 5. The Team

Security personnel would be the members of this team. The Leader of the team is DGM (Security and Vigilance)

Functions

A) Leader

1. After getting information, arrange for cordoning of affected area and deploy manpower for this purpose.

2. Consult IC / SC and decide the locations for assembly of persons . 3. Guide the team members in adopting a particular procedure-like cordon, traffic control,

entry of key and other required persons.4. Consult IC/SC and decide the traffic movement in the plant .5. Arrange Police help in consultation with IC/SC for control of traffic and public outside.6. Allocate the team members to particular locations and brief them how to control the

traffic.7. Ensure availability of PPE for the Team members and self.8. Inform district authorities and get their help for evacuation, closing certain roads, for

maintenance of law and order.

B) Team Members

1. The security person stationed near the affected area will reach at site and take charge for security.

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2. Stop unauthorised entry at site and inside the plant.3. Allow entry of only emergency vehicles- fire brigades, ambulance etc.4. Receive the help under mutual aid members and direct such persons to the affected

site.5. Barricade the incident site and control the traffic movement 6. Follow the traffic signs and rules during an emergency.7. Understand and follow procedure for wearing PPE.8. Guide the traffic as instructed by the team leader, using proper signs.9. Curb the panic among people.

2.5.3 Medical Management Team

Leader of the team is Medical Officer on duty. The CMO will ensure all medical arrangements including first aid box, trained first-aiders, antidote, ambulance, etc. and necessary arrangement as per Factory Act and Punjab Factory Rules (as applicable in Haryana) in Occupational Health Center. CMO will have to maintain and display the list of trained first-aiders as per Annuxure-6. The following medical arrangements should be made by the Doctor and his team. The assistance of trained first-aiders would be taken in handling the victims. The medical management team and trained first-aiders are as per the Annexure –6.

1. Rush to the site with stretcher, first aid equipments and trained first aid persons.2. Depute the trained first persons in dispensary.3. Keep the required medicines in readiness and ensure that they would be available at

any time. 4. Ensure the readiness of all medical equipment at all times.5. Tie-up with nearby hospitals and maintain a list containing 24-hour telephone numbers.6. Arrange transportation for victims / injured/ affected person to the hospitals. In this

regard, the Doctor would work closely with Asstt. Manager Transport.7. Administer first-aid and if required send the victims to the nearby hospital for further

treatment. 8. Supervise the first aid being rendered. 9. Get in touch with IC/ SC for any type of medical aid required.10. Keep details / records of the hospitalized person.11. Ensure proper medical help is given to the victim.12. Make necessary arrangement with nearby hospital(s) to treat victims if their number is

large. 13. Maintain records of affected persons, treatment given to them, etc.

2.5.4 Facilities Team

Leader of the team is DDVM (PHR). The role of this team is to provide the necessary common facilities for mitigation of emergency and safe operation of the plant. The activities of the Facilities team includes facilities for –

1. Rush to ECC. 2. Assess the situation in consultation with IC/ SC.3. Transportation (both personnel & equipment and relief materials).4. Communication including telephones.5. Arrange for canteen services for personnel on duty as well as affected once like Food &

refreshments etc.6. Assess and maintain law and order situation.

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7. Arrange for temporary shelters for those evacuated and their rehabilitation.8. Arrange for help of security personnel for cordoning off the affected area, for fire fighting /

rescue help and evacuation of casualties.9. Arrange for head counts of employees, contractors, transporters and visitors.10. Informing and assisting the relatives of persons involved in emergency. 11. Keep the employees informed in township and seek their help if necessary12. The Management has constituted this core team of facilities personnel as per Annexure- 7.

2.5.5 Maintenance Team

Team

The leader of the maintenance team is DDVM (PCM). Each unit has a team to control the operations in the area or shut it down as per the advice of the Site Controller. This team will assist IC in management of the incident. The team will include the departmental head as per Annexure-8. The DPM will ensure availability of personnel like mechanical fitters/ maintenance personnel, electricians and pipe fitters, pump operators, etc. The composition of the team is given in Annexure - 8.

Functions

A) Team Leader

1. Report to ECC.2. Assess the emergency situation and guide the team members accordingly. 3. Keep liaison with other tem leaders and coordinators for requirement of their services

if any.4. Consult SC and inform him the latest development and information of the situation.5. Direct action to restore facilities, repairs, demolition as required under the

circumstances6. Ensure shutting off supply of electricity to the affected areas if so required.7. Get necessary equipment’s like cranes, dozers, trucks, welding and cutting set etc as

needed for tackling the emergency and make available required personnel to operate above facilities.

8. Make sufficient number of contractor workers available to do civil jobs, like filling sand bags, making bunds, closing drains, excavation & required for the emergency.

9. Keep workshops / facilities open with necessary personnel throughout emergency to cater any need for repairs of additional equipment.

10. Make arrangements of temporary lighting / emergency lighting for affected areas, shelters and other places of assembly, keep liaison with HSEB.

11. Know and understand Operating Procedures for controlling or shutting down various operations.

12. Ensure that the team members also know and understand the Operating Procedures.13. Guide the team in efficiently controlling/shutting down the operations in consultation

with SC.

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14. Keep the contact details of all the team members handy, especially for any specific operation vis-a-vis persons, so that they can be contacted when not on duty.

15. Ensure that sufficient number of different categories of skilled personnel is available and used for the purpose.

16. Ensure own safety and the safety of team members.

B) Team Members

1. Know, understand and follow the direction of the leader.2. Contact the other team members for any assistance/ help.3. Arrange to restore facilities, repairs, demolition as required under the circumstances4. Arrange shutting off supply of electricity to the affected areas if so required.5. Use necessary equipment’s like cranes, dozers, trucks, welding and cutting set etc as

needed for tackling the emergency and make available required personnel to operate above facilities

6. Arrange civil jobs, like filling sand bags, making bunds, closing drains, excavation & required for the emergency.

7. Keep workshops / facilities open with necessary personnel throughout emergency to cater any need for repairs of additional equipment.

8. Make arrangements of temporary lighting / emergency lighting for affected areas, shelters and other places of assembly, keep liaison with HSEB.

9. Preserve record and other evidence, which may be required for inquiry.

2.5.6 Coordination through Emergency Control Centre

The lists of key personnel of the factory who have a role as emergency support & technical team is given in Annexure-9.

The list and telephone directory of senior officials of the factory is given in Annexure- 10. The list and telephone directory of key Government Officials and response services is given in Annexure- 11. Besides SC, other senior officers whose services may be needed either for providing advice or for implementing decision made by the SC should be readily available and accessible. On declaration of the emergency, all the key personnel should report to the ECC .

2.5.7 Natural Calamities Crisis Control

The chances of Earthquake and Storm/Cyclone are there. For quick response to such natural events a Disaster Management Team has been formed in the factory. The team mainly consists of fire, security and medical (first-aid trained person), etc.

The Team

Head - Security is the team leader. Under his guidance team is formed as per Annexure -12.

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Functions

A) Team Leader

i) Guide the team members to handle the crisis due to natural calamities.ii) Allocate the team members to different locations and brief them about their

responsibility.iii) Inform senior officers about the warning so that everybody can take necessary

steps to avoid losses/preserve important documents, computers, etc., if they are in low-lying areas.

iv) Confirm whether the dewatering pumps are in good working condition and sufficient fuel oil is available for running them when required.

v) In case of cyclone warning, collect information from the collector office about data.

B) Team Members

i) Know, understand and follow the operation process to evacuate the people from the place.

ii) Always consult and take guidance from the Leader.iii) Bring any injured persons to the plant Dispensary.

2.5.8 Liaison with External Agencies

MEO-ADMIN would be the authorized spokesperson of the factory to deal with any external agency such as District Collector, Directorate of Industrial Safety & Health (DISH), govt. officials, media, etc.

Functions

1. Keep in touch with SC.2. Keep important telephone numbers handy and ensure that they are updated.3. Keep in touch with different agencies and brief them about the situation and ask for help, if

required.4. Inform injured persons relatives.

2.5.9 Assembly Points & Head Count

The leader of assembly points & head count team is DPM (EMR). He will update and maintain the details of head count team as per Annexure-13. The persons, those are not part of immediate response teams, would evacuate their work area and report at the designated Assembly Point. The decision to evacuate the work area will be taken by SC after getting feedback from the Incident Controller. Evacuating visitors would be the responsibility of the

concerned officer. Department Head should take care to evacuate any handicapped person in his area.

Locations

There are two assembly points AP-1 and AP-2 in the factory. These points are indicated in the Plant Layout drawing (see Annexure-13).

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Assembly

PointLocation Who should Assemble

AP-1 Area between parking and Fire Station Decision would be taken by the SC after consulting the IC

AP-2 Near JV Gate

Responsibility for Head-Count

A two-member headed by DPM (EMR) will man the designated Assembly Points. These persons would carry out the head-count and report any unaccounted person to the ECC. He will take the help of concerned DPMs for employees and contractors employees and DPM vigilance for visitors. Concerned DPMs will rush to assembly point along with list of employees and contractor personnel present in that particular shift.

Functions

(1) Appeal people to remain calm and assemble without causing panic.(2) The status of the person reported at the Assembly Point to be maintained as per

Annexure-14.(3) The status of non MSIL persons to be maintained as per Annexure-15.(4) The detais of missing persons to be maintained as per Annexure-16. This list will be given

to rescue team to search and rescue from the probable location and inform to ECC.

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3. EMERGENCY CONTROL CENTRE

The Emergency Control Centre (ECC) is a place from where the Site Controller (SC) would provide direction/guidance and co-ordinate various agencies/activities to effectively handle the emergency situation.

Depending on the location of the emergency site and the prevailing wind direction, the SC will decide and use one of the two Emergency Control Centres for handling and controlling the emergency. He will then proceed to that ECC and take overall control of the emergency. All the key personnel (except IC and the persons he would need) would assemble in ECC. While selecting the location of ECC, due care has to be taken that it should not fall under any risk.

3.1 Location of ECC

The ECC is located at the following two locations: Fire Station (marked as “E-1” on the plant layout drawing) Alternate ECC Near JV Gate (marked as “E-2” in the plant layout drawing).

3.2 Equipment/Facilities available in ECC

The equipment and facilities provided in the main ECC and the Alternate ECC are identical. These are mentioned in Annexure-17.

3.3 Manning of ECC

1. Site Controller (SC) or his Alternate

2. Assistant to SC

3. Telephone Attendant

4. Three Messengers

5. The members to be present at ECC as per Annexure-18.

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4. PLANT RISK EVALUATION

4.1 Hazardous Chemicals, inventory and location

Maruti Suzuki India Limited is an automobile industry manufacturing vehicles. The main thereat to the factory is due to fire and explosion due to LPG/PNG. The hazardous chemicals used in the factory are listed in Annexure-19.

4.2 Properties of the Hazardous Materials

The properties of the hazardous materials may be referred in Material Safety Data Sheets (MSDS) given in Annexure-20.

4.3 Likely Dangers to the Plant Major occurrences that may cause danger to the plant are enumerated below: Possible Emergencies in the factory

Emergency

Area Parameters and Safety Measures

Fire & Explosion

LPG Bullet Yard Pressure: 4.2 kg/cm2 (62 psi); Temperature: Ambient For maintaining temp below 33 deg.C continues

water spray system is installed All flameproof electric fittings Provided with fire extinguishers and water hydrant

monitors around the storage areaLPG/ PNG pipeline Pressure: 2.3 kg/cm2 (30 psi); temperature: ambient

All flameproof electric fittings Provided with fire extinguishers

Paint and Thinner Godown

Stored at atmospheric pressure in a 20 kg tins. Provided fire extinguishers Flameproof electric fitting

Fire Paint Shop Automatic CO2 flooding System Provided fire extinguishers Flameproof electric fitting

Gas Turbine Area Automatic CO2 flooding System Provided fire extinguisher

Spillage and Fire

Diesel/Oil storage Pressure Atmospheric; Temperature: Ambient Hydrants are provided Storage tanks provided with a pressure cum vacuum

valve

All of the above may lead to temporary or permanent damage to the plant and also the surroundings.Incidents having off-site implications can be because of:

Natural calamity like earthquake, cyclone, flood, etc. Air raids/ crashing of aircrafts or flying objects. Sabotage

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The major hazards can originate from one or a combination of the following: Slow isolated fires Fast spreading fires Explosions Bursting of pipe lines/ high pressure vessels

Fire Hazard

Throughout the plant Cables in trenches or on trays in all plant sections Fuel, LPG. Paints, Thinners storages and handling in the plant.

Other Incidents

Other incidents, which can also result in a disaster, are: Agitation/forced entry by external group of people/vandalism Bomb explosion

4.4 Fire and Explosion inside the Plant and also outside, if any

Risk Analysis has to be carried out with an aim to estimate the distances likely to be affected in case of a LPG release or in case of Fire in HSD storage area. The scenarios considered as:

Scenario-1: Catastrophic Failure of fully stored 2O MT LPG Bullet, resulted into BLEVE.

i) Blast Wave Consequences of BLEVE

The reading radial distances from the LPG vessel (r) vs peak overpressure on the target (P) are shown in the following table.

r (M) P (bar)32 3.040 2.057 1.070 0.784 0.5

107 0.3142 0.2234 0.1275 0.08335 0.06469 0.04586 0.03820 0.02

1340 0.01

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The risk assessment study indicates that the thermal radiation flux on a target for the intensity of 4.0 and 12.5 kw/m2 are at a radial distances from the LPG bullets for the BLEVE scenario are 475 and 225 meters respectively.

The thermal radiation flux of 4.0 kw /m2 represents burn injury to exposed people whereas 12.5 kw/m2 represents hazard range for property damage. It may be borne in mind that the duration of exposure to the present described BLEVE scenario would be 10 seconds.

Scenario – 2: Failure of Liquid LPG Discharge Line at the Bottom of the Storage Bullet

In accordance with the procedure described for the BLEVE scenario the blast effect in terms of r & P are shown in the following table:

r (M) P (bar)

3.5 3.0

4.4 2.0

6.3 1.0

7.7 0.7

9.2 0.5

11.8 0.3

15.7 0.2

25.8 0.1

30.5 0.08

37.0 0.06

52.0 0.04

65.0 0.03

90.0 0.02

148 0.01

The epicenter of the explosive vapour cloud will be at a distance of 26.6 from the leak source in the downward direction. Beyond the distance of 56 – 5 m from the leak source in the downward direction will be safe zone in aspect of encountering a source of ignition.

Scenario – 3: Pool Fire Scenario of HSD Storage

It is seen that the radiative flux capable of causing secondary fire (12.5 kw/m2) is confined within the pool fire. The thermal hazard range for the radiation flux of 4.0 kw/ m2 is 24 m from the centre of pool. Thus for such a pool fire scenario the fire fighting is to be done beyond this distance. However, due to higher flash point of HSD (B class petroleum), the probability of occurrence of such fire is very low, as the requirements of the controller of explosives have been implemented for the storage.

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Scenario – 4: CNG Pipeline Failure at GAIL TerminalIt is assumed that in the event of failure of the pipeline (16” Diameter) the gas escapes at the maximum supply rate of 5 lac m3 per day, which amounts to be the gas release rate of 3.7 kg/s.The epicenter of the gas closed explosion for the present scenario will be 90 m away from the leak source in the downwind direction of the assumed velocity of the wind to be 2 m/s.

Scenario – 5: Failure of 6” CNG Pipe Line from GAIL Terminal to the Plant The maximum distance from the release source for lower explosive limit is 63 m and for

upper explosive limit is 33 m The mass of methane in the explosive range is 9.3 kg. The characteristic explosive length (Lo) is 1.0m

Scenario – 6: CNG Pipeline Failure of CNG GAIL Terminal Radial distances from the epicentre of the explosive cloud are 40 m and 23 m from thermal radiation flux of 4.0 Kw /m2 and 12.5 kw / m2. The thermal radiation flux of 4.0 kw / m2

represents the range for burn injury to people whereas 12.5 kw/m2 represents hazard range for property damage; however the duration of exposure is limited to 2-8 seconds only.Summery of Risk analysis is given as Annexure – 21

4.4.1 DISASTER RISK RATINGS FOR VARIOUS SUBSTANCES / CHEMICALS

SL. NO.

NAME OF EACH SUBSTANCES/CHE

MICALS USED, HANDLED,

PRODUCED AS INTERMEDIATE OR END-PRODUCTS, RAW MATERIALS

ETC.

CHEMICAL FORMULA

FLASH POINT

O C

BOILING POINT

O C

TOXICOL-OGICAL RATING VALUE (TOX)

FIRE RATING

(Fe)

REACTIVITY RATING

VALUE (Re)

1. LPG C3H8 & C4H10

(Mixture)104.4 Propane

-60 Butane>-40 1 4 0

2. CNG Mixture -292F (-180C) : -285F (-61C)

(Estimate)

1 4 0

3. Diesel Complex mixture of

Hydrocarbons

32 to 96 150-400 0 2 0

4. Furnace oil Complex mixture of

Hydrocarbons

185-500 66 C and above 0 2 0

5. HCl HCl NA : 53C (127F) 3 0 26. Caustic7. Paint Complex

mixture of Hydrocarbons

13°C 73-146°C 0

8. Thinners Above 30 C (Closed cup)

>120 C 3

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4.5 Area Risk Evaluation

Within 2 km radius of Maruti Suzuki india Limited, Gurgaon , the communities in the vicinity will be affected in the event of emergency at the LPG Storage Area is given in Annexure-22.

4.6 Natural Calamities which can lead to emergency

4.6.1 Earthquake

Gurgaon falls under the seismic zone-IV, which has a fairly high seismicity. As a result of high intensity earthquake, which can trigger into a technological disaster, includes collapse of LPG storage tanks, leading to fire and explosion.

Earthquake cannot usually be forecasted and therefore precautions immediately prior to such event are not usually possible. Apart from some of the counter-measures to be taken in foreseeable cases, emergency recovery plans shall be considered by the emergency management team as per the situation and site conditions.

4.6.2 Cyclone/Storm

The contingency actions during a cyclone shall be based on the weather forecasts obtained from meteorological stations and the local meteorological department. Some of the important actions to be carried out are as follows:

Prior to Cyclone

Establish regular contact with the local meteorological department. Establish distances from storm in order to execute preparatory actions in a shorter time. Appraise the factory operations / installations and consider the consequences that the

emergency might have on operations and personnel. Check the availability of tools, batteries, non-perishable foods and other materials that

might be required. Review all operations carefully to ensure that systems in jeopardy are taken care or shut

down. Ensure the readiness of emergency vehicles, medical centre, medicines etc. Storage tanks should have products to the maximum filling capacity and secure tanks /

pipelines firmly against floating. Metallic sheets, loose materials, empty drums and other light objects shall be properly

secured. Flush drainage systems.

During Cyclone

Remain calm.

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Do not go outdoors. Do not seal the office completely as the suction created by the difference in atmospheric

pressure inside and outside can rip open a window or door by breaking window glass panes.

After The Cyclone

Do not touch electric lines. Stay away from the disaster area. Take special precautions in driving vehicles since the under-pavement could cave in due to

the weight of automobile.

4.6.3 Flood

Though flood in this region is rare by virtue of its location from rivers and dams, there is every possibility that the factory can be flooded due to a heavy downpour. As a result, the low lying areas are likely to be affected. Following actions may be considered during such situations: Make decision to shut down the plant and related facilities if the situation demand. Identify swimming experts to evacuate the trapped personnel. Switch off all electrical supply until the situation comes to normal. Ensure adequate communication facilities are made available. Monitor all open drainage systems for inadvertent entry of water stream. Check that no oil enters the final water stream from the effluent treatment plants and storm

water ponds. Ensure adequate de-watering pumps are made readily available. Medical team to monitor hygiene and sanitation facilities and take steps to prevent spread

of any communicable diseases.

4.7 Air Raid

Air raid warning would be obtained from the District Emergency Authority and Defence Authorities during which total blackout of the entire complex should be considered. Some of the contingency actions to be considered during those occasions are as follows:

The Aviation Lights installed on highest point inside the factory shall be switched off. All the lighting on the Streets shall be put off. All the plant lighting shall be put off. Brown curtains shall be provided for all windows inside the building. Other emergency actions shall be followed in addition as per the general procedure.

4.8 Bomb Threat

In view of the recent targets of the terrorist groups, the possibility of receiving bomb threats to the industry cannot be ruled out. Therefore, consider all bomb threats as genuine and act accordingly keeping in mind the safety of the people in the power plant and the property. For such situation, the security people will take action under the guidance of Captain Deepak Anand. The Bomb threats may be received in writing or may be received on phone. The expected actions from the team are as follows:

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1. Keep the caller on the line as long as possible. Request him to repeat the message, listen carefully as every word spoken by the person has to be recorded mentally or penned down.

2. If the caller does not indicate the location of the bomb or the time of possible detonation, it is advisable to try to ask him for this information.

3. Inform the caller that the building is occupied and the detonation of a bomb would result in death or serious injury to many innocent persons.

4. Pay particular attention to peculiar background noises such as motors running, background music and any other noise which may give a clue as to from where the call is being made.

5. Listen closely to the voice (male, female), voice quality (calm, excited), accents and speech impediments. Immediately after the caller hangs up, report should be made to the immediate senior manager or security officer on duty about all the above details.

6. The other member can immediately inform the Police and Bomb diffusion squad.7. If location identified, cordon-off the area and ask people to leave the area.

* * *

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5. NOTIFICATION PROCEDURES AND COMMUNICATION SYSTEM

5.1 Communication System

Any employee noticing an unusual event such as LPG/PNG Leak or Fire should immediately act as follows:

Shout and warn other about fire/emergency or break the emergency glass of Manual Call Point if available.

Dial 3456 or 3500 from the nearest telephone. State his name and exact location of the emergency. Contact affected Plant Officers of the area incident has occurred. The person reporting the incident will remain near the location to guide emergency crew

arriving at the scene.Or

He will inform the security control room at 2277 / 2288 or nearest security staff. The security will inform to Fire Station.

The reporting and information sequence will be as per Annexure –23.

While giving the message, the person should:

1. Identify oneself2. State briefly the type of emergency, i.e. whether fire, explosion or a toxic release.3. Give the location of the incident4. Estimate the severity of the incident and return to the area of incident and await instructions

from Duty Officer In-charge.5. Check wind direction and move crosswind of the incident site.6. The standby to render all required assistance

5.2 Declaration of emergency

5.2.1 Localized Emergency

The emergency situation arising in any section of one particular shop/ area which is minor in nature, can be controlled within the affected section itself, with the help of in-house resources available at site and fire department.

Such emergency does not have the potential to cause serious injury or damage to property / environment and the domino effect to other section of the affected plant or nearby plants/ areas.

5.2.2 Major Emergency

The emergency situation has the potential to cause serious injury or damage to property/ environment within the affected plant or to the nearby shops and/or whole complex.

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On-Site Emergency Management Plan & Disaster Control Measures of Maruti Suzuki India Ltd., Gurgaon 5.1Such emergency situation always warrants mobilizing the necessary resources available in-house and/or out source to mitigate the emergency.

5.2.3 Immediate Actions for Major Emergency1. After receipt of call about emergency IC will rush to the incident site.2. Take appropriate action to control the situation.3. After assessing the situation he would inform to Fire Brigade / ECC. 4. Fire Operator will inform to Fire Officer / Safety Officer / Chief Safety Officer and DPM

(SNW).5. Depending upon location of emergency either ECC1 or ECC2 will be selected as a

control point by Chief Safety Officer/ Safety Officer.6. If found beyond control, the IC will inform the SC. 7. SC would contact Fire Operator in the fire station / ECC1. 8. The Fire Operator in the fire station would inform the identified members of ECC

(emergency key personnel). 9. SC would then rush to the identified ECC. 10. After assuming the position of SC in ECC, he shall contact with other senior members

in the plant. 11. SC will make communication set up with IC about the situation. After communication

with IC, if it is beyond the control 12. SC would declare an Emergency and inform fire station for actuating a siren. 13. After receipt of phone call or message from SC, the Fire Operator available at the Fire

Station will blow the siren with wailing sound for 30 seconds 3 times.

The siren is also connected to a battery set so that it can be operated in case of a power failure or outage. The switching to battery in case of power failure or outage is automatic. The siren is located at the Fire station.

5.2.4 All-Clear Siren

1. When the emergency situation has been brought under control and the area is safe.2. “ALL-CLEAR” siren would be activated after clearance from the SC in consultation

with the IC. 3. It would be a continuous sound of the same pitch for a duration of 30 second.

5.2.5 Fire pump operation Plan

EM-3: On sounding the alarm, DM Plant will start the Fire Water Pump (if hydrant is not pressurized). If need arises, the diesel fire water pump to be started and will monitor the water pressure in hydrant and at site.

5.2.6 Security

1. On sounding the emergency siren, reach the emergency site. 2. Control and monitor movement of personnel and vehicles according to emergency

zone. 3. Depute 3 messengers to ECC after discussion at fire station.4. To encircle the incident site and stop movement of vehicles and persons excepting

those on fire and emergency duty.5. All type of work involved work permit system must be stopped.6. Mobile equipment like cranes, operating inside the affected zone must be shut off after

properly lowering the equipment hanging from the booms.

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5.2.7 Fire Volunteers

After hearing siren, employees belonging to fire squad (fire volunteers) have to proceed to the incident site and report to shift in-charge of fire at site.

5.2.8 Other Personnel

Personnel not belonging to emergency organization (not required for emergency handling directly) to proceed to local assembly point and wait for further instructions

5.3 Sequence of Actions after Declaration of Emergency

(1) After declaration of an emergency, SC will discuss with MEO (ADMIN) to notify the nearby Hospitals and Police Station and also for seeking help from other Government Offices and NGOs.

(2) The SC contacts IC on intercom to know about the incident.(3) The maintenance team approaches the incident site to attend emergency.(4) The other plant In-charges occupy their office to receive instructions from SC.(5) The other teams carry out their respective functions.(6) SC should interact with the IC and other senior persons in each plant / site.(7) IC in consultation with the other team leaders informs the situation to SC.(8) SC in consultation with the IC and other key personnel decides whether to stop the

plant or not.

5.4 COMMUNICATION

5.4.1 Persons

The Fire Operator in Fire Station / ECC or other identified person will act as ECC operator.

5.4.2 Responsibilities

ECC Operator

1. To receive all incoming calls, note them down in the format “Record of Telephone Messages” as given in Annexure-24.

2. Give message to the fire staff to rush to the site.3. Inform the situation to immediate superior of fire brigade and safety officers.4. After getting call from IC, will inform back, the action and situation to IC.5. To telephonically contact SC and other persons as required by the Plant’s Incident

Controller or IC 6. To ensure that communication system is always kept in good working condition.7. To keep records of all incoming and outgoing calls.

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On-Site Emergency Management Plan & Disaster Control Measures of Maruti Suzuki India Ltd., Gurgaon 5.35.4.3 Communication of Emergency

Communication to persons inside the factory and outside is considered to be very crucial for effective handling of the emergency.

5.4.4 Communication to Personnel within the Plant

As the emergency develops, it becomes necessary to communicate with personnel all over the factory such as personnel in the affected area, personnel in other threatened areas, and more importantly, the key personnel.

Communication can be by one or more of the following means: Actuating the siren (as detailed above), Declaration of emergency and Implementation of emergency procedures

Another means is to give specific instructions, using public address system, intercoms or messengers. However, direct communication is better effected through a walkie-talkie system, especially between the IC and SC.The IC briefs the SC about the status of the incident or emergency, its likelihood to affect other plants and also the areas beyond the fence. He also discusses with SC the approach he would follow in controlling the incident. The SC, through the intercom system, remains in contact with other key personnel and briefs them on the strategy he would like to follow and seeks their views and as well as instructs them on emergency response.

5.4.5 External Communication

5.4.5.1 Key Personnel not immediately available at the Site

SC gets in touch with the key personnel through external telephones and instructs them on emergency response action.

5.4.5.2 Communication to nearby communities

SC establishes telephonic contact with the identified (pre-determined) key persons in the neighbouring communities. Public address system will be used for announcing in the nearby areas.

5.4.5.3 Communication to nearby industrial units

SC establishes telephonic contact with the identified (pre-determined) key persons in the neighbouring industrial units. Public address system will be used for announcing in the nearby areas

5.4.5.4 Communication with Local Authorities and Emergency Response Agencies

The SC and Divisional Head - HR, if deemed fit, shall inform the local authorities such as District Collector; Police, Fire Brigade, Directorate of Industrial Safety & Health; etc.

5.4.5.5 Names and Telephone Numbers of key personnel and emergency response agencies

A telephone directory has been prepared and kept at strategic places such as; ECC, entrance gate, plant offices.

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On-Site Emergency Management Plan & Disaster Control Measures of Maruti Suzuki India Ltd., Gurgaon 5.45.4.5.6 Designated Persons for Media Contacts

MEO-ADMIN (or his Alternate) would be the company spokesperson for interacting with media (newspapers, TV channels, etc.).

5.4.5.7 Procedure for notifying families of injured persons

Communication to the families regarding injury/fatality would be the responsibility of MEO (ADMIN). The messages would not make the family panic but give the factual information as to where the inured are receiving treatment.

5.5 Central Reporting Office

ECC would be the Central Reporting Office during the emergency.

* * *

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6. PREVENTIVE SAFETY MEASURES, EMERGENCY EQUIPMENTS AND FACILITIES

6.1 Preventive Measures and Safety Status Currently in Practice

6.1.1 Preventive measures and safety practices prevailing in plant:

Safety Work Permit Systems:

Safety Work Permit (SWP) system is followed in the company to control the behavior and unsafe acts of employees. All new, maintenance/repair works having high potential of accident/injury have been identified and covered under Safety Work Permit. The SWP is designed for the following activities after careful consideration to ensure safety of workers, co-workers in the vicinity and also the safety of plant & machinery. Hot Work Permit Permit to work at Height / civil / excavation Vessel / confined space Entry Permit Work Permit - Electrical

Safety Training Programmes

Safety training is provided to the Company employees as well as contractor employees from time to time by internal as well as external facilities. Under Company’s unique policy, no new entrant or promote is confirmed in higher scale unless he undergoes safety training

Regular Mock drills are conducted

Regular mock drills are conducted to check and evaluate the effectiveness of preparedness, action and mitigation efforts

Safety Committee Meetings are conducted

Central Safety committee and the departmental safety committees are constituted to ensure participation and active support of workers in safety management. Regular meetings of safety committees are conducted. Status of safety activities and accident prevention programme is discussed in the committed meetings.

Safety coordinators are designated in each department and their regular meetings are conducted. Safety related activities are carried out and monitored through coordinators in their respective work areas.

Risk assessments of all hazardous installations is carried out

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House Keeping is maintained throughout the plant.

GOOD HOUSE-KEEPING is considered as an important & integral part of all the activities of the factory. Good House Keeping competitions are organized every year to motivate and involve employees for Good house keeping.

Safety Inspections

Both statutory & non-statutory are carried out periodically. Based on inspection reports, suitable actions are taken to minimize chances of emergencies.

Personal Protective Equipments are provided to the workers as per the requirement. Adequate inventory of both respiratory & non-respiratory PPEs is maintained. These PPEs are kept at easily approachable strategic locations for use in case of any emergency.

Incident / Accident Report

The idea of this incident / accident report is to record all abnormal unusual events, which may or may not likely to danger the lives of the persons working or cause property damage and in order to take appropriate corrective measures in time to avoid the recurrence of such incidents in future.

Investigation Report

All accidents are investigated to find out the remedial measures and record of investigation is maintained. Accident statistics is prepared and analyzed.

Lifting Equipments and Pressure Vessels Testing

Lifting equipments Pressure vessels and are tested and examined periodically and record is maintained. Immediate remedial action is taken if any defect is observed during test and examination.

Periodic Maintenance & Preventive Maintenance Schedule

All equipments and machines are being checked on daily, weekly, monthly and yearly basis and preventive maintenance activities are performed base on assessment and requirement, well in advance to prevent occurrence of any incident. Equipments are kept in good condition by taking timely actions.

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6.1.2 Disclosure of Information to Workers and Details of Public Awareness System in Existence or Anticipated

6.1.2.1 Disclosure of information to workers is ensured by following activities:-

(a) Safety Training of Personnel

Safety training and re-training of employees is a regular activity in the factory

Safety training includes following topics also:

- First-Aid- MSDS and properties of chemicals- On-site Emergency Plan including mock drill- Fire Prevention and fire Fighting with practical demonstration - Accident Prevention - Machine and process safety procedures- Electrical safety- Safety in hand tools- Machine guarding- Use care and maintenance of PPEs- Housekeeping, - Safe driving,- Material handling etc.-

(b) Safety Committees

Central Safety Committee:-

Safety Committees are constituted. The company safety Committee has equal participation of workers and management representative. It meets at least once in three months or as and when the need arises. SHE related issues are discussed in the meeting. Management supports safety committee recommendations and implemented accordingly. All safety related issues including risk , remedial measures and emergency preparedness and management systems are discussed and communicated to all members which are further disseminated to all workers through safety committee members.

Departmental Safety coordinators Committee

Contractor safety Coordinators committee

(c) Safety Day Celebration

National Safety Day is celebrated with great enthusiasm on every 4th Mach to create safety awareness amongst employees. Awards are distributed to the winners.

(d) Safety Propagation

Safety Poster, slogans and Essays competition is arranged and the winners are awarded . The same is displayed at conspicuous locations to make known to all the persons working in the plant.

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On-Site Emergency Management Plan & Disaster Control Measures of Maruti Suzuki India Ltd., Gurgaon 6.36.1.3 Public Awareness and Disclosure of Information to Public

It has been planed to educate the general public likely to be affected in the event of emergency. Safety officials and HR personnel shall prepare the plan with the help of deptt concerned. Properties of chemicals their effects symptoms and the first aid treatment / precaution to be observed shall be explained to the general public. Help of the district administration will be sought to educate the people.

(i) Method to Educate the Public for Facing any Possible EmergencyTo be prepared in collaboration with the District authorities, however Company will extend all possible help to them.

(ii) Details of Factory Emergency Warning System for the General Public PA system and Siren will be used to communicate the emergency to the nearby public.

6.2 Fire Fighting

6.2.1 Equipment

Assessment of the fire equipment for handling any foreseeable emergency has been done. Accordingly, fire equipments including portable fire extinguishers have been installed at various locations. Further, the areas having potential to lead to major emergency are covered by the fire hydrant system. The details about type, capacity and number of extinguishers are given in Annexure-25.

6.1.2 Trained Fire Persons (Fire Volunteers)-

The employees are also trained in the use of the portable fire extinguishers. List of the trained employees is maintained in the departments. This list would be reviewed regularly and updated in the department by the concerned safety coordinator. In case of fire / emergency, the fire volunteers and safety coordinators will immediately proceed to the incident site.

In the event of fire alarm / siren / fire / any such call, the pump house operations will be attended immediately by the designated pump house operator of EM3 and the persons identified in each shift will work as a Fire-pump attendant. On hearing the Fire Alarm, the team immediately proceeds to pump house for immediate response.

6.3 Emergency Medical Facilities

6.3.1 Medical Arrangements

The Medical Response Team would be led by the Medical Officer. Two qualified doctors are employed in the factory. One will be available from 0715. to 1600 hrs and other for 1600 to 2400 hrs. The doctors would be helped by the two pharmacists. In case of any emergency, the safety coordinator will guide the first aid trained persons of the department / area to reach at incident site and will work under the supervision and direction of doctor. The doctors will liase with the IC or SC. After giving first-aid, the injured person would be brought from the incident site to the plant Dispensary. The names and telephone numbers of the trained first-aid trained persons are given in the Annexure – 6.

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On-Site Emergency Management Plan & Disaster Control Measures of Maruti Suzuki India Ltd., Gurgaon 6.4The Medical Officer would periodically interact with nearby hospitals as necessary. He would also ensure that the required medical supplies, equipment, antidotes, etc. are available at the dispensary and also in these hospitals where the injured person may have to undergo treatment.

Medical Facilities available in MSIL

- 3 Bedded medical ward

- One minor OT

- Two Ambulances equipped with emergency facilities

- Medical Store –emergency medicines & Antidotes

- Stretchers

- First Aid Boxes- available in dispensary and shops/ deptt .

List of antidotes in dispensary:-

SN NAME OF ANTIDOTE Qty

1 Inj. Atropine

2 Inj Soda bi carb

3 25% Glucose

4 Inj Decadron

5 Inj Avil

6 Inj Frusemide

7 Inj Diazepam

8 Inj Fortwin

9 Inj Diclofenac Sod.

10 Inj Stemetil

11 Inj Adrenaline

12 Inj Deriphylline

13 Inj Ranitidine

14 Inj Paracetamol

15 I / V Fluids

16 Anti snake Venom

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6.3.2 Ambulance

There are two ambulances in the factory and both are kept near the factory Dispensary. Whenever there is an emergency ambulance is sent to the site and with the help of first-aid trained person and brought to the factory dispensary.

6.3.3 Multiple Casualties Handling

In the event of a disaster involving multiple causalities, help of nearby hospitals/doctors and their paramedical staff would be available. Company Doctor shall arrange such help from the outside whenever required. The list of the hospitals is given in the Annexure–26.

6.4 Wind Direction Indicators

A windsock has been provided near LPG Tank Farm and emergency control centres in addition to the other appropriate areas to indicate the prevailing wind direction.

6.5 Mutual Aid and Response Group (MARG):-

In case of a major emergency the MARG members would help each other. Though there is no agreement between them but voluntarily they respond during emergency. The Fire and Rescue leader will assess the incident situation and if the situation goes beyond the control, he will call for assistance from the Mutual Aid Partners directly. The members are:

i) 503, SU, AF Station, Arjangarh, New Delhiii) 25 WG, AF, Rajokri, New Delhiiii) AFSCTS, Gurgaoniv) Civil Fire Brigade, Gurgaonv) Maruti Fire Service, Gurgaon

* * *

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7 RESTORATION OF NORMALCY

7.1 Authorisation

Only SC is authorised to take the decision to “call off” the emergency only after consulting the Incident Controller and other key personnel that the situation is under control and the emergency is over. He will then order to actuate the ALL-CLEAR siren.

7.2 Declaration of the end of Emergency:

The emergency would be considered to have ended on the actuation of “ALL-CLEAR” siren.

7.3 Communication of the Declaration or the End of Emergency

All persons within the Plant are informed through the “ALL-CLEAR SIREN”. External agencies, viz. District Collector Office, Factory Inspector Office, Police, and Civil

Defense etc. are again contacted by SC or his Alternate to communicate the end of emergency.

Inform by SC to the Corporate/Head Office about end of emergency.

7.4 Restoring Normalcy

When the “ALL-CLEAR” siren is sounded, it indicates end of emergency. However, each plant shall resume to normal operation after assessing the situation and by following the laid down procedures.

7.5 Sequence of Actions after the “ALL-CLEAR SIREN” is actuated

i) SC contacts all plants to communicate them the emergency has been called off and instructs for actions required to be taken by the person inside.

ii) The senior person in each plant takes a small meeting of all his workers and briefs them and instructs them to go back to their workplaces or as directed by SC.

iii) The IC in consultation with SC and senior-most official of the Plant takes necessary steps to resume normal work.

iv) Plants start operation as per the laid down procedures.

* * *

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8 TRAINING AND DRILLS

8.1 Training

Training would be undertaken as follows:

i) Training of Team Leaders: All the Team Leaders would undergo training in the following areas:

a) Knowledge of hazardous chemicals stored, handled and used; their physical and chemical properties, MSDS, what to do during emergency related to the chemical, etc.

b) Procedure for reporting emergency

c) Siren System

d) Location-wise types and the numbers of fire extinguishers, and how to use them, etc.

e) Types, numbers and locations of different types of PPE (including SCBA and fire suit), situations where they should be used, method of using, etc.

f) Fundamentals of rescue and first aid.

g) Evacuation Procedure, i.e., assembling at the designated Assembling Points, head-count, their records, followed by method of evacuation.

h) Documentation of emergencies.

ii) Training of Emergency Responders

Different emergency responder teams would be given in-depth training on the various aspects of responses such as Fire Fighting, Rescue Operations, First Aid, Medical Response, Traffic Control, Head-Count at Assembly Point, etc.

iii) Training of Team Leaders, Incident Controller and Works Main Controller.

A training workshop should be conducted to understand not only role of individual Team Leader, but also issue of coordination, chain of command, etc. through simulation and Table-Top Exercises. Periodic refresher training would also be needed.

iv) Training Programme on how to conduct Emergency Drills.

The above training would be periodical. The Chief Safety Officer, in consultation with General Manager, would decide the periodicity.

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8.2 Emergency Drills

The emergency response plans and emergency preparedness level would be tested through the following drills: -

1. Table-Top Exercise (TTE)2. Functional Exercise (FE)3. Full-Scale Exercise (FSE)

All elements/procedures of the On-Site Emergency Plan would be first tested through TTE and perfected to the extent possible. The Plan then would be modified/ updated. Functional Exercises basically to ensure proper functioning of various equipment such as the fire-fighting equipment and the fire hydrant system. The Full-Scale Drill would be conducted to know the level of preparedness of all teams. Initially, TTE and FE would be conducted at least once a month.

The following drills are conducted periodically:

Plant Emergency Drill for LPG emergency Fire Drills Plant Emergency Drills (fire scenario involving evacuation)

8.3 Periodicity and Responsibility

Sr. No.

Type of Drill Frequency Responsibility

1. LPG Leak Once in a six month Chief Safety Officer3. Fire Once in a month -do-4. Plant Emergency (fire

scenario involving evacuation)

Once in a year -do-

After each drill, there should be a critical review by all participants (including the drill observers). All suggestions and recommendations should be noted for future reference. These should be the basis for the periodic review and updating of the Emergency Management Plan. This way the plan gets more and more refined and updated.

* * *

_________________________________________________________________________


9. REGULAR TESTS OF EMERGENCY PROCEDURES

As mentioned against sec. 8.2 above, drills, regular tests of functioning of Emergency Organisation as well as procedures would be carried out through exercises based on simulated emergencies. Besides these exercises, the tests would include –

i) Siren System – The Siren System would be tested at 10.00 a.m. on every Monday, observations noted and corrective actions would be taken. The testing would include – activation system, intensity of the siren at different places so that all in the Plants, etc distinctly hears it.

ii) Breathing Apparatus Sets – Breathing Apparatus Sets would be tested for leak-proof and supply of air for the rated time. This would also be done once in two month by the Fire Officer.

iii) Portable Fire Extinguishers – Testing of operation of different types of fire extinguishers and their periodical inspection, repair/ replacement of parts, etc. would be done as per the approved schedule. All the fire extinguishers would be subjected to inspection periodically, i.e. every month and record of such inspection would be maintained. This also includes testing and operation of the portable fire extinguishers that can be done through conducting drills. It would serve benefit of testing the operation and at the same provide the personnel in testing their skill in handling these equipments. Record of such drills would be kept. The prime responsibility for the testing, inspection and examination is with Fire Officer.

iv) Evacuation Practice – How to assemble at Assembly Points; take head count and transporting them to a safe place. This practice would be done once in a year. A list of Vehicles available for transporting people in case of evacuation is required is listed as per Annexure-27.

* * *

_________________________________________________________________________


10 - PLAN UPDATES

It is necessary that the on-site emergency plan be tested periodically. As mentioned under Chapters 8 and 9, the testing of the plan would be through Table-Top Exercises, Functional Exercises and Full-Scale Drills.

10.1 Review of the PlanThis plan is a dynamic document and would be reviewed/ updated in the following situations: -i) The plan would be tested from time to time (details given under Sec. 8.2). Short comings/

lacunas that would be surfaced during testing of the plan, would be recorded/ documented, discussed during debriefing session following the test, decisions are taken to include them in the plan.

ii) If case of addition, modification, alteration of plant operations leading to change in the quantum of risk associated with hazardous operations / installations, the plan would be modified / updated. Such changes shall be approved by the factory manager and occupier.

10.1.1 Information updatesi) The circular / office order of any organisational change / transfers, will also be sent to Chief

Safety Officer by the H.R. Department for making necessary change in OEP.ii) Any changes in the organisational structure, contact details such as addresses, telephone

numbers, emergency team members / key persons etc., shall be made and approved by the Chief Safety Officer in the plan.

10.2 ResponsibilityUpdating the Plans would be the responsibility of the Chief Safety Officer as mentioned in 10.1 and 10.1.1.

10.3 ProcedureThe Plan would be updated after approved by the factory manager and occupier in writing. The Chief Safety Officer would submit the proposal as mentioned in 10.1 above to the Factory Manager and occupier. After approval, the plan will be circulated to the concerned authorities/ persons. The information of changed will be circulated in the prescribed format mentioned in Annexure 39

10.4 Controlled Copies of the PlanThe On-Site Emergency Plan when approved by the management of the Maruti Suzuki India Limited, sufficient number of copies would be printed; each copy would be identified by a certain number and issued to different persons who have roles to play during the emergency. A register would be maintained indicating which identified copy is issued to a specific person. Complete responsibility of getting the management’s approval, printing a number of copies, giving them identification numbers, issuing them, registering the issue, would be the responsibility of the Chief Safety Officer. It will also be his responsibility to replace the copies after each modification by giving them identification numbers and re-registering them. This is required to ensure that only up-dated copies are with different personnel. A list of Controlled copies of the Plan is listed as in Annexure-28.

* * *

_________________________________________________________________________

On-Site Emergency Management Plan & Disaster Control Measures of Maruti Suzuki India Ltd., Gurgaon 10

11 EMERGENCY RESPONSE PROCEDURES

11.1 Communication

i) Refer Chapter 5 for communication for notifying an On-Site Emergency.ii) Channels of Communications

11.2Evacuation Procedure

The Evacuation Procedure is in two parts, viz. assembling at the designated Assembly Points, head-count and transporting to safer place.

i) All the non-essential persons are advised by the respective in-charge to assemble at Pre-identified Assembly Points.

ii) Public address system existing in the plant will be utilised for directing the people for evacuation and other emergency responses / instructions.

iii) The designated persons would take head count.iv) As per instructions to the staff taking the head counts the assembled persons are allowed

to leave after noting down their names and plant.

11.3 Medical

The rescue team brings the injured persons after giving them first aid to the dispensary on stretchers. The medical staffs treat them. However, if medical officer finds that the injured requires treatment, which cannot be provided locally, medical officer will send the injured person/s by ambulance to the pre-identified, pre-informed nearby hospital. He keeps on informing about the conditions of injured to the SC from time to time. He is also responsible for providing training to first-aid team, medical and paramedical staff.

11.4 Utility Failure Procedure

Utilities such as water supply, power, and fuel gas are considered very important and hence continuous supply is required to be ensured during emergency. Power supply is required basically to equipment with which emergency is handled. Therefore, power supply to such equipment is ensured through use of batteries or separate power supply using DG sets. A person is deputed at each of the utilities for this purpose. Two DG sets are provided for emergency supply.

11.5 Individual Division Emergency Procedure

Each of the Plant has developed an Emergency Procedure and Response Plan procedure giving what is to be done in case of emergency occurring in the unit or if it occurs in some other units. Accordingly, the people from the division would act during an emergency. The workers are made aware of the procedure by circulating the same and also displaying at conspicuous places in the Plant.

* * *

_________________________________________________________________________


12. INFORMATION FOR USE IN THE OFF-SITE EMERGENCY PLAN (A Section for use in Off-site Emergency Plan)

1. Summary of Risk Analysis, vulnerability zone for those scenarios, which can escalate into off-site emergencies.

See Annexure – 21

2. List of resources required to handle the off-site emergencies foreseen in the On-site Plan, their assessment of the adequacy.

i) Ambulance – 2 no.ii) Breathing Apparatus.iii) Security van.iv) Fire Extinguishers

3. If own resources (such as equipment, trained man-power, medical help, etc.) are not adequate to meet such off-site emergencies, what is the arrangement (formal or informal) made to get the additional resources (e.g. Mutual Aid or arrangement with the Public Response Agencies) mentioning the salient terms of such arrangements.

There is an informal agreement with the Mutual Aid Partners. The members are:

i) 503, SU, AF Station, Arjangarhii) 25 WG, AF, Rajokriiii) AFSCTS, Gurgaoniv) Civil Fire Brigadev) Maruti Fire Service

4. What resources can be spared by the industrial unit for use in the Off-site Emergency arising out of on-site emergencies of other units and what is the arrangement for releasing such resources.

Dy. Manager (Fire) is authorized to take decision to help the MARG. One Fire tender would be deployed for an outside emergency.

5. How Community awareness programme has been planned? How the community has been identified (from which zone-part or full vulnerability zone)? Have the key opinion makers who can play active role have been identified? (Give list along with their contact details). Has the selection of the community or that of key persons in the community been done in consultation with the District Authority? etc.

6. Has Insurance under the Public Liability Insurance Act been obtained? Give summary.

_________________________________________________________________________


7. Designate a Contact person who would be authorized to co-ordinate for Off-site Plan and his contact details

Sl.No.

Name and Designation Telephone No.

Office Residence Cell phone

1Mr. D.D. Kala Chief Safety Officer

2340099 4037375 9873914557

23

8. Technical Team (chemical-wise) in case of an Off-site Emergency took place due to escalation of an On-site incident, contact details of its members.

* * *

_________________________________________________________________________


ANNEXURES

DESCRIPTIONANNEXUR

E NO.PAGE NO.

Information about the Factory 1 13.1Layout of the Factory 2 13.2Fire and Rescue Team 3 13.3Rescue coordinators (safety coordinator) 4 13.4-13.5

Security & Vigilance Team 5 13.6

Medical Management Team 6 13.7

Facility Team 7 13.8

Maintenance Team 8 13.9

Emergency Support & Technical Team 9 13.1Telephone directory of senior officials of the factory 10 13.11List of Key Government Officials and Response Services 11 13.12-13.13

Natural Calamities Crisis Control Team 12 13.14

Location of Assembly points and Team members 13 13.15Record of persons reporting at the Assembly Point 14 13.16Details of Persons other than employees (Contractors, vendors, suppliers, transporters, visitors etc

15 13.17

Summary and identification of missing persons (if any) 16 13.18

Equipments and Documents kept in ECC 17 13.19-13.20Manning of ECC 18 13.21Inventory of Hazardous Chemicals 19 13.22Material Safety Data Sheet 20 13.23-13.48Summary of Risk Analysis 21 13.49-13.61Area Risk Evaluation 22 13.62Communication Procedure 23 13.63Format for recording telephone messages in ECC 24 13.64List of Fire Fighting Equipment 25 13.65-13.66List of Hospitals 26 13.67-13.69List of Vehicles Available 27 13.70-13.74Controlled Copies of the On Site Emergency Plan 28 13.75List of Personal Protective Equipments 29 13.76

Cyclone/Flood Emergency Procedures 30 13.77-13.78

Earthquake Emergency Procedure 31 13.79

Special Equipment Available Nearby 32 13.8

List and telephone directory of NGO 33 13.81-13.82Telephone directory of mutual aid group/ others 34 13.83Emergency evacuation procedure for general employees 35 13.84Telephone directory of nearby contact person in community (Villages) 36 13.85Telephone directory of nearby contact person in industries 37 13.86-13.87Record of amendments 38 13.88Format for communicating the changes in emergency plan 39 13.89Details of persons involved in preparation of On Site Emergency plan 40 13.9Abbreviations used 41 13.91Glossary of terms 42 13.92-13.93

________________________________________________________________________

On-Site Emergency Management Plan & Disaster Control Measures of Maruti Suzuki India Ltd., Gurgaon 13

Annexure - 1

INFORMATION ABOUT THE FACTORY

Full Name & Address of the company : MARUTI SUZUKI INDIA LTD Palam Gurgaon Road, Haryana.

Factory Registration No : GGN / M – 165 / 6967

Principal Activities: - Manufacturing of Automobiles.

Classification of Industry as per National Code: - Manufacturing of Passenger cars and utility vehicles

Phones : Factory : Reg. Office : Fax No. : Full Name & Address of the Occupier :

Mr. TSUNEO OHASHI. MEO(DIR)-PROD and Occupier,Address- Maruti Suzuki India Limited, Palam Gurgaon Road, Gurgaon (Haryana)

Telephones Off. Res./ Mobile

(0124)- 2346822

9811819083

Full Name & Address of the Manager :

Mr. M M SinghMEO (PROD) and Factory Manager,Maruti Suzuki India LimitedPalam Gurgaon RoadGurgaon (Haryana)

Phones :Off. Res./ Mobile

( 0124 ) - 2342617 (0124)-2389261 M-9810314395

Name of the shift Company Employee Contractor Apprentice Vendor Dealer/ Trnsptr

TotalMale Female Total Male Female Male Female

First (A) 0845 to 1600 hrs General (G) 0845 to 1730 hrsSecond (B) 1600 to 0045 hrsThird (C) 0045 to 0715 hrs

Total 4520 151 4671 4164 | 18 498 | 4280 13631First contacted in the case of any emergency

Fire Department 3456 or 3636

_________________________________________________________________________


Annexure - 2

____________________________________________________________________________________________________


Annexure - 3

FIRE AND RESCUE TEAM

Sl.No.

TeamName &

DesignationIntercom Office Resi. No. Mobile No

1. LeaderMr. Inder Pal, Dy. Manager

3456,35000124-

2340099011-

255933269810106348

2. MemberMr. S.C. Patel,

Supervisor3456,3500

0124-2340099

0124-2267467

9891911555

3. MemberMr. Sunil Kumar,

(FIREMAN)3456,3500

0124-2340099

0124-2357424

9891456813

4. MemberMr. G.D.V. PRASAD,

(FIREMAN)3456,3500

0124-2340099

0124-2355673

9911195673

5. MemberMr. ANIL KUMAR,

(FIREMAN)3456,3500

0124-2340099

0124-2266204

9811433175

6. MemberMr. DINESH

KUMAR, (FIREMAN

3456,35000124-

23400990124-

23055209891911333

______________________________________________________________________


Annexure - 4

Safety Coordinators (Rescue Coordinator)

SN DVN DEPTNAME OF SAFETY

COORDINATORSTAFF

NOLVL INT COM Ph No(R/M)

1 BDE TRD PRAMOD TIWARI 143375 12 4194 9891154031

2 BDE TRD P R GANGWAR 107093 10S 4194 9891810647

3 EED EAE J P SINGH 193500 11 3458 9911927103

4 EED CEE BILGI VITHAL 190918 12 3641 9999300712

5 EED MCE AGARWAL RAJIV 186368 12 3474 9891900614

6 ERD1 EN1T SANTOSH SINGH 179744 13 4169 9899413899

7 FCGE ES1 VILAS NARKHEDE 134465 12 3548 9911311241

8 FCGE ES2 ASHUTOSH GUPTA 176246 12 3419 9810292971

9 FCGE ES3 A K MAGO 110388 11 3531 9811834550

10 FCGE MC1 PRAVEEN GUPTA 120227 13 3417/3412 9911512541

11 FCGE MC2 S K SHARMA 124605 13 3597 9811710102

12 FCGE MC3 P K MITTAL 125474 13 2462 9871633549

13 HR VGL JAGDISH KUMAR 149420 11 3421 9899767672

14 IT SND A S BAINS 136263 12 2398 9811569979

15 IT IOS M. CHAKRABORTY 126250 9S 3528 9899369500

16 KBE KBX B P SINGH 104159 13 9911684331

17 KBE CAS DARSHAN SINGH 133574 8S 9911177654

18 KBE KBE MAHENDER KUMAR 135720 9S

19 KBE KBM PAUL MOHINDER JAGDEV 128023 10S 9868125267

20 PCON MSD K K ARORA 109428 13 3506 9811524750

21 PCON ECS RAJESH GAUTAM 113867 12 9899131960

22 PHR ADM C P SHARMA 101311 10S 2253 9811804400

23 PHR SNW RAJESH KUMAR KAIM 189740 9S 3500 9810699962

24 PLG1 AS1 HARISH CHAND 143448 12 3516 9911347294

25 PLG1 MX1 R S BHANDARI 129186 10S 3552 9818564857

26 PLG1 PS1 Y P AHUJA 123340 11 3454 9868603373

27 PLG1 WS1 C N SAI KUMAR 143413 13 2241/2327 9958657474

28 PLG2 PRS SATISH KUMAR KAUSHIK 143308 12 2251 9911967491

29 PLG2 AS2 MANISH GUPTA 148415 13 2417 9811158138

30 PLG2 MX2 R C JADON 113476 11 2419 9811708898

31 PLG2 PS2 T N SINGH 107581 10S 2205 9811799183

32 PLG2 WS2 MAHABIR SINGH YADAV 108855 10S 2404 9911552476

33 PLG3 AS3 RUMEL SINGH 111511 10S 2472 9911141511

34 PLG3 MX3 V K SHARMA 131849 12 2462 9899456099

35 PLG3 PS3 S V KRISHNAN 107638 11 2448 9811403708

____________________________________________________________________


SN DVN DEPTNAME OF SAFETY

COORDINATORSTAFF

NOLVL INT COM Ph No(R/M)

34 PLG3 MX3 V K SHARMA 131849 12 2462 9899456099

35 PLG3 PS3 S V KRISHNAN 107638 11 2448 9811403708

36 PLG3 WS3 RAM SINGH KHOLA 150010 7S 2407 9891948257

37 PLG3 PAU DAS SUKHENDU 175536 12 4101 9810316711

38 PMNT MP1 RAJIV GARG 188034 12 2311/2281 9910563903

39 PMNT MP2 S PRABHAKAR 172057 13 2469 991134060540 PMNT MPC V M SARAN 118540 13 3618 991120944541 PRDS EM1 R R MALIK 159662 MGR 2279 9811803362

42 PRDS EM2 L C SHARMA 118729 13 2307/2257 9810357631

43 PROJ CVL S K PURI 107417 10S 3401 9891179769

44 PROJ EM3 RAMINDER SINGH 107549 11 2269/4136 9911310839

45 QAIN VI-G1 K BALARAJU 106895 10S 3402 9810923049

46 QAIN VI-G2 GYANCHAND 115193 10S 2409 9891774838

47 QAIN VI-G3 RAMESH CHAND 121886 10S 2470 9911100767

48 QAIN QA1 K SUBODH JAIN 106658 13 4118 9811084266

49 QAIN QA2 ANURAG KALRA 185337 12 9868150425

50 QAIN QA3 MUTHU SOLAIAPPAN 187526 12 9899798177

51 QAIN QA3 U B NAYAR 140686 13 4174 9891918417

52 QAIN QA4 SACHIN KUMAR 187100 11 9899290429

53 SER SR4 GANESH BABU 124591 13 2299 9891948960

54 SPR WAD RAMESH CHANDER 128368 10S 2362 9999363631

xxx


Annexure - 6

MEDICAL MANAGEMENT TEAM

Medical Team

Name Intercom Office Resi. No. Mobile No

Dr. RAVI AGGARWAL (CMO) 3559 0124-2346122 0124-5039335 9811839335

Dr. P.K. BHATT , Adviser-Admn-

(CMO)

3559 0124-2346122 0124-5067439 9811810439

Mr. SATISH, Pharmacist 3514

Format of the list of the first trained persons having valid certificate is given below:-

SN Name ( Sh)Staff No

Level Deptt.Intercom

Phone number

AddressTrg period

_______________________________________________________________________________


Annexure – 7

FACILITY TEAM

SN TEAM LEADER DESIGNATION INTERCOM OFFICE RESI MOBILE

1. C S RAJU (Leader) DDVM [ PHR ] 2447/ 2248 4100375 2580580 9818898597

2. ANIL GAUR(Alternate leader)

DPM [ EMR ] 2493 4383081 9811888038

3. SOMNATH MUKHERJEE

L-13 [ EMR ] --- --- 9999000859

4. ANURAG DWIVEDI L-12 [ EMR ] 3696 2349148 9999637375

5. L RAJENDRAN L-11 [ EMR ] 3690 9999088895

6. AMIT THAKUR L-11[ HRD ] 9212748009

7. AMIT JAIN L-10S [ EMR ] 2276 9811524499

8. AJIT TANEJA Welfare Officer 3426 2387764 9810761462

9. SANJIV KUMAR SINHA

L-13[ HRD ] 9873579100

10. S K BHATIA L-12 [ HRD ] 9811982727

11. RAJIV ADYA L-10S [HRD] 2283 4013858 9810141442

12. UMA KANT L-9S[ HRD ] 2400 2342507 9899708063

13. R K KHATTER L-13 [ ADM ] 2253 2397693 9811610244

14. O P JUYAL L-11 [ ADM ] 3465 2341181 9873076652

15. RAJESH GUJRAL L-11 [ADM] 2273 9811792248

16. KARAM BIR SINGH

L-10S [ ADM ] 2253 2397693 9811349801

17. C P SHARMA L-10S [ ADM ] 2253 2397693 9811804400

* * *

________________________________________________________________________


Annexure – 8

MAINTENANCE TEAM

Sl. No.

Team Name DesignationContact Numbers

Office Res Mobile

1.Leader VIKRAM

KHAZNCHIDDVM (PMNT) 3501

2360012 4250905

9810182186

2. Leader(Alternate)

S R RANA DPM (EM1) 41022347477, 2358836

9810119936

3.Member

K C KHATRI DPM (MPC) 3444 9810295412

4.Member

V K ARORA DPM (MP2) 3439/2281 40485070 9810245449

5. Member P V KRISHNA DPM (MP1) 3439 4048985 9891085369

6 Member SANJAY BARONIA DPM(EM3) 2289 9810414784

7 Member L N RAO DPM (EM2) 4136 2380309 9213127435

8 MemberDEEPAK MAHESHWAI

DPM (CVL) 3401 2340328 9873004154

* * *

_________________________________________________________________________


Annexure – 9

EMERGENCY SUPPORT AND TECHNICAL TEAM

Sl. No.

Contact Numbers

Team Name Designation

Office (Int.)

Office Cell

1 Leader S Y SIDDIQUI MEO (ADMIN) 2268 2341181 9811729786

2Leader (Alternate) C S RAJU DDVM (PHR) 2248 2349148 9818898597

3 Leader R DAYAL EO (PE) 3572 2341405 9811801000

4Leader (Alternate)

VINAY VARSHNEY DVM (PRDS) 3467 2349410 9810210607

5 Leader AJAY SETH DVM (FIN) 2392 2399016 9811668454

6 Leader - PLG1 D S SHARMA DDVM (PLG1) 2205 2340112 9810088348

7 Leader - PLG2 M K ROSUL DDVM (PLG2) 2205 2340112 9810838274

8 Leader - PLG3 K S JOHAR DDVM (PLG3) 2448 4015606 9810043510

9 Leader- FCGE VIKRAM VERMA DDVM (FCGE) 3550 2349438 9811373979

10 MemberSANJAY BARONIA DPM(EM3 ) 3583 4392289 9810414784

11 Member D. D. KALACHIEF SAFETY OFFICER 3500 2340099 9873914557

12 Member SANJAY KHARE DPM (SNW) 3500 2340099 9911211165

13 Member DEEPAK JAIN DPM (EM4) 2289 9810223478

14 Member K KULKARNISAFETY OFFICER 3500 2340099 9958181251

15 Member K SONWANESAFETY OFFICER 3500 2340099 9911238567

16 Member RAJESH KAIMSAFETY OFFICER 3500 2340099 9810699962

* * *

______________________________________________________________________


Annexure - 10

TELEPHONE DIRECTORY OF SENIOR OFFICALS OF THE FACTORY

SN

NAME OF KEY PERSONS

DESIGINATION

INT COM

OFFICENo.

MOBILE No.

1 S NAKANISHI MD 2201 2340336 9799999594

2 TSUNEO OHASHIMEO (DIR) -

PROD &OCCUPIER

3480 2346822 9811819083

3 M M SINGH MEO (P)-Factory

Manager2479 2342617 9810314395

4 S Y SIDDIQUI MEO (ADMIN) 2268 2341181 98117297865 R DAYAL EO (PE) 3572 2341405 98118010006 AJAY SETH DVM (FIN) 2392 2399016 98116684547 V VARSHNEY DVM (PRDS) 3467 2349410 98102106078 I V RAO MEO (ENGG) 2315 2346121 9811709599 S MAITRA MEO (SC) 3590 2342315 9811864477

10 RAJESH UPPAL DVM 3428 2340306 981007191211 RAJIV GANDHI DDVM 3485 4107726 981013813312 M GOPALKRISHNAN MGR 2224 4382974 9818096349

* * *

_________________________________________________________________________


Annexure - 11

LIST OF KEY GOVERNMENT OFFICIALS, RESPONSE SERVICES

ADMINSTRATION

Officer's Designation Office Residence

Commissioner, Gurgaon Division

2324033, 2324023, 2321572

Deputy Commissioner, Gurgaon

2321144ISDN : 2314970

2320508(FAX),2303333

City Magistrate, 2320305 2320405

Civil Surgeon 2322412 2321702

Secy. Red Cross, Gurgaon 2320468 2310468

I.G.P. Gurgaon Range 2320777 2324765

Sr.Supdt. of Police, Gurgaon 2320221,2321777 2331800

S. E. Public HealthGurgaon

23209882320972

2320928

G.M. Haryana Roadways, Gurgaon

2320222, 23223912322432 (Work Manager)2320304 (Fax)

2314591

Zilla Sainik Board 2320730

PBX Exchange 2321777, 2320221 2330700(fax)

Supdt.of Police, (Vig), Gurgaon

2321428 2321607

_________________________________________________________________________


IMPORTANT TELEPHONES (OFFICES)

FIRE HOSPITALS

Control Room 2320100 CMO Gurgaon 2322412, 2321702

Control Room 100 Civil Hospital 2320102, 2320680

Fire Station Rail Vihar 2310710 Kalyani Hospital 2303101, 2303102

Fire Station Bhim Nagar 2398868 ESI 2320513, 2322285

Fire Station, Sector 29 2398101 Pushpanjali Hospital

2320050, 52, 2327953

Fire Station 2392201 Aryan Hospital 2323845

Fire Station 2392102 Saraswati Hospital 2320191, 2326191

Civil Defence 2322136 Lal Nursing Home 2322410

POLICE THANA / STATION OF GURGAON DISTRICT

Police Station Designation Phone Nos.

SHO PS City, Gurgaon Inspector 2321496

Sadar Gurgaon Inspector 2201476

Udyog Vihar Gurgaon Inspector 2340200

DLF Gurgaon Inspector 2396700

PS Manesar Sub-Inspector 2290100

PS Bilaspur Sub-Inspector 2379580

* * *

_________________________________________________________________________


Annexure – 12

NATURAL CALAMITIES CRISIS CONTROL TEAM

Sl. No.

Team Name with Designation Contact Numbers

Intercom Res./ Cell1. Leader Capt. Deepak Anand

(DPM - VGL)2233 9910173500

2 Leader(Alternate)

Mr Jagdish Kumar (Asst.Mgr) 3421 9899767672

3 Member R K TYAGI (Assig Mgr.) 3532 9911388066

4 MemberMr C D Sharma (Supervisor) 2233 9971141385

5. MemberMrs Anjna Choudary (Supervisor) 2233 2340110

6. MemberSecurity Controller 2277, 2288 2340053, 4018727

7. Member Security Controller 2277, 2288 2340053, 4018727

8. Member Security Controller 2277, 2288 2340053, 4018727

***

_________________________________________________________________________


Annexure-13

LOCATION OF ASSEMBLY POINTS AND HEAD COUNT TEAM

AP Location to report

Accommodation

Capacity

Identified Person In-charge

Name Deptt.Main /

Alternate

Telephone

Off. Res./Cell

AP-1& 2

Fencing & JV Gate

ANIL GAUR DPM (EMR)

Over all -Main Leader

2493 9811888038

AP-1& 2

Fencing & JV Gate

SOMNATH MUKHERJEE

L-13 Over all- Alternate Leader

2248 9999000859

AP-1 Fencing Gate

3000 G P MALHOTRA

L-13 Main Leader

3696 9999637375

AP-1 Fencing Gate

3000 AMIT JAIN L-10S Alternate 2276 9868320820

AP-2 J.V. Gate 3000 RAJESH KUMAR

13 Main Leader

AP-2 J.V. Gate 3000 SANJAY SHARMA

12 Alternate

ASSEMBLY POINT TEAM MEMBERS – As designated by Team Leaders of EMR

AP-1Fencing Gate

AP-1Fencing Gate

AP-1Fencing Gate

Authorised person by IC / DPM of affected area.

AP-2 J.V. Gate

AP-2 J.V. Gate

AP-2 J.V. GateAuthorised person by IC / DPM of affected area.

***

_________________________________________________________________________


Annexure- 14

Record of persons reporting at the Assembly Point Assembly Point No. __________________

Location of the Assembly Point __________________________________________

Day & Date: __________________________ Time: __________________________

Noted by: _________________________ Head Count by ______________________

(A)-Details of company employees:-

SN Number of Employee of MSIL

Any Other Person (Make a tick (_/) Mark)

Deptt. Total Reported on AP

On emergency duty

Missing

Contractor Visitor Supplier Any OtherTotal Repo

rted on AP

On emergenc

y duty

Missing

Total Reporte

d on AP

Missing

Total Reported

on AP

Missing

Total Reported on AP

Missing

1.2.3.4.5.6.7.8.9.10.11.

***

_________________________________________________________________________________________________________


Annexure-15

(B)-Details of Persons other Than employees (Contractors, vendors, suppliers, transporters, visitors etc):-

SN Number of contractor’s Employee Any Other Person

Name of contractor Related Deptt.

Total Reported on Assy Point

On emergency duty

Missing Visitor Supplier Any OtherTotal Report

ed on AP

Missing

Total Reported on

AP

Missing

Total Reported on

AP

Missing

1. 2.

3.4.

5.6.

7.8.

9.10.

11.12.

13.14.

15.16.

17.18.

19.20.

21.22.

23.24.

25.26.

27.28.

29.30.

31.32.

33.34.

***

_________________________________________________________________________________________________________


Annexure- 16

(C ) Summary and identification of missing persons (if any)

SN Name Name of Department /

contractor agency)

Department Concern Probable Department / Location

1.2.3.4.5.6.7.8.9.10.11.12.13.14.15.

* * *

_________________________________________________________________________


Annexure - 17

ITEMS / EQPT. AND DOCUMENTS KEPT IN ECC

A) Following Plans would be displayed in the ECC

i) Details of inventories of hazardous material e.g. location, maximum quantity, type of storages, etc.

ii) Works Layout indicating therein location of ECCs, Location wise / Type wise / Capacity wise portable fire extinguishers, Assembly Points, Canteen, Dispensary, etc.

iii) PPE - Location wise, Type wise numbers.

iv) Roads prominently marked on the layout indicating exits

v) Area Map showing surrounding areas especially sensitive population such as schools, public places, hospitals etc.

B) Plans kept in ECCs that can be used as the emergency and corresponding emergency actions developed.

- Affected Area- Area Evacuated- Emergency Vehicles & Equipment- Safe Escape Routes towards assembly points- Other relevant information.

C) Important phone Nos

i) Contact No. of SC (Intercom & Resi/ Mobile No.)ii) Contact No. of ICs (Intercom & Resi/ Mobile No.)iii) List of contact No. of Government officialsiv) List of contact No. of Mutual Aid personsv) Contact No. Mahanagar Gas Ltd.vi) Contact No. Reliance Energy Ltd.vii) Contact No. of MTNL Telephone exchangeviii)Contact Nos. of Transporters/Vehicle Providersix) Internal Intercom directory

D) Documents and equipments in ECC

Two telephone lines with one line dedicated to only outgoing calls and the other for incoming calls.

ECC -1 Tel. No. 2340099-------- (for outgoing calls)Intercom 3456 / 3636--- (for receiving calls)

ECC – 2 Tel. No. ----------------- (for outgoing calls) Intercom ------------- (for receiving)

_________________________________________________________________________


1. Wireless communication equipment.

2. Important telephone numbers (Police, Hospitals, District Collector, Industrial Safety & Health, Chief Controller of Explosives, etc.) painted on a board and displayed conspicuously in the ECC.

3. A separate directory of key personnel, giving contact details such as their intercom telephone number, residential telephone number, and cell phone number

4. Nominal roll of employees

5. Extension of public address system

6. Note pads, pencils, erasers and other stationery for sending or recording messages giving format (refer Annexure-15) for recording telephone messages.

7. Copies of On-Site Plan & Disaster Control Measures.

8. Torches, umbrellas, raincoats, essential PPE (including one SCBA), etc

9. Tape recorder (optional)

10. One PC with e-mail, Internet and web site facilities

11. Conference table with Chairs

12. Layout Drawings showing Pipeline Corridor/ Process Units, Assembly points, etc.

13. Reports of Risk Assessment with Consequence Analysis

14. CO2 system details

15. Inventory of Hazardous materials

16. MSDS of Hazardous Chemicals

17. Emergency Lighting

* * *

_________________________________________________________________________


Annexure-18

MANNING OF ECC

S N Name / DesignationTelephone No.

Office Office / Cell

1 Telephone attendant -(Fire service) 3456/ 3636 0124-2340099

2D D KALA- Chief Safety Officer

3500 9873914557

3 PRAVEEN GUPTA- FMGR (SNW) 3500 9810210562

4SANJAY KHARE DPM - (SNW)

3500 9911211165

5Site Controller –M M SINGH - MEO (Production)OR

2479 9810314395

6Site Controller –(Alternate)RAJIV GANDHI- DVM (CEP)

3485 9810138133

7 Assistant to S CDILIP SHARMA- ( PDS )

2479 9811462526

8VIKRAM KHAZANCHIDDVM (PMNT)

3405/3501 9810182186

9VINAY VARSHNEY- DVM(PRDS)

3467 9810210607

10Media contacts-S Y SIDDIQUI - MEO (ADMIN)

2268 9811729786

11Media contacts-(Alternate)C S RAJU – DDVM (PHR)

2208 9818898597

12 R DAYAL -EO(PE) 3572 9811801000

13 AJAY SETH- DVM(Finance) 2392 9811668454

14 DEEPAK JAIN – DPM (EM4) 2289 9810223478

15 SAFETY OFFICERS

16AJIT TANEJA -Welfare Officer (Rehabilitation) 3426 9810761462

17 Messenger 1- security control room 2277 /2288

18 Messenger 2 - security control room 2277 /2288

19 Messenger 3 - security control room 2277 /2288

* * *

_________________________________________________________________________


Annexure-19

INVENTORY OF HAZARDOUS CHEMICALS

Sr.

No

Name of the

Chemical

Details of Largest

storage tank.

Type and

No. of Storage

Tanks

Location Total

Capacity

Capacity Type of

storage

1. LPG storage 20 MT Bullet Overhead Bullet – 3 nos.

Grid 2E GT AREA

60 MT

2. CNG filling 800 sm3 Grid 1F GT AREA

3. Diesel 300 KL Tank Tank – 2 nos. G T AREA 600 KL4. Furnace Oil 150 KL Tank Tank – 2 nos. G T AREA 300 KL5. Auto LPG Storage 7500 lit Bullet UG Bullets – 2

nos.G T AREA 15000 lit

6. HCL Storage 13.5 m3 Tank Tank G T AREA 13.5 m37. Caustic Storage 2.46 m3 Tank Tank EM3 DM PLT 2.46 m38. Paints and Thinner 15,000 lit Individua

l drums 20 lit drums 15,000 lit

* * *

_________________________________________________________________________


Annexure - 20

MATERIAL SAFETY DATA SHEET

LPG1. CHEMICAL IDENTITY

Chemical Name Liquefied Petroleum Gas Chemical Classification

Hydrocarbon Mixture

Synonyms LPG, Propane, Butane, Propylene, Purofax, Bottled Gas

Trade Name LPG

Formula C3H8 & C4H10 (Mixture)

C.A.S. NO. 68476-85-7 UN NO. 1075

RegulatedIdentification

Shipping Name

Codes/Label

Hazardous wasteI.D. No.Hazchem Code

Petroleum Gases, Liquefied

Flammable, Class 2

2 WEHAZARDOUS INGREDIENTS

C.A.S. NO. HAZARDOUS INGREDIENTS

C.A.S. NO.

1. Propane 74-98-6 3. Propylene 115-07-1

2. Butane 106-97-8

2. PHYSICAL AND CHEMICAL DATA

Boiling Point/ Range oC

Melting/ Freezing Point oC

> -40

Not Pertinent

Physical State

Vapour pressure@ 35 oC, mm Hg

Gas at 15oC and 1 atm

Not available

Appearance

Odour

Colourless

Mercaptan added as an odouriser

Vapour Density(Air = 1)

1.5 Solubility in water @ 30 oC

Slight Solubility in others

Soluble in Organic Solvents, Alcohol

Specific Gravity(Water = 1)

0.51 – 0.58 at 15 oC pH Not pertinent

____________________________________________________________________________


3. FIRE AND EXPLOSION HAZARD DATA

Flammability

TDG Flammability

Yes

2

LEL (%V)

UEL (%V)

1.9%

9.5%

Flash Point (OC) oC

Flash Point, (CC) oC - 104.4

Auto ignition Temperature oCExplosion Sensitivity to ImpactExplosion Sensitivity to Static ElectricityHazardous Combustion productsHazardous Polymerization

466.1 Propane, 405 BunateNot establishedMay explodeEmits CO, CO2

Does not occur

Combustible Liquid No Explosive Material

No Corrosive Material

No

Flammable Material Yes Oxidiser No OthersPyrophoric Material No Organic

PeroxideNo

4. REACTIVITY DATA

Chemical Stability

Incompatibility with other material

Stable

Strong OxidisersReactivity

Hazardous Reaction Products

No reaction with common materials but may react with oxidising materialsNot available

5. HEALTH HAZARD DATA

Routes of Entry Inhalation, SkinEffects of Exposure/Symptoms

Concentration in air greater than 10% causes dizziness in few minutes. 1% conc. Gives the samesymptoms in 10 mts. High concentration causes asphyxiation. Liquid on skin causes frostbite.

Emergency Treatment Seek medical aid immediatelyInhalation If inhaled, remove the victim to fresh air area. Provide

artificial resuscitation.Contact Skin : Remove the wetted clothes & wash the affected

area with plenty of waterEyes : Flush with plenty of water for 15 min.

LD50 (Oral-Rat), mg/kg Not listed LD50 , mg/kg

Permissible mg/kgExposure Limit ppm

Not listedNot listed

Odor Threshold, ppm mg/kg

5000 to 20000

TLV (ACGIH) ppm mg/kg

10001800 mg/m3

STEL, ppm mg/kg

Not listedNot listed

NFPA Hazard Signals Health1

Flammability4

Reactivity/Stability0

Special

_________________________________________________________________________


PREVENTIVE MEASURES

Personal Protective Equipment Avoid contact with liquid or gas

Handling and Storage Precautions Provide hand gloves, safety goggles, gas mask, protective over-clothing and shoes

6. EMERGENCY AND FIRST AID MEASURES

FIRE Fire Extinguishing Media

Special Procedure

Unusual Hazards

CO2, Dry Chemical Powder, Water spray.

Keep the containers cool by spraying water if exposed to fire or heatIf not cooled sufficiently, containers will explode in fire.

EXPOSURE First Aid Measures

Antidotes/ Dosage

If inhaled, remove the victim to open air area and artificial resuscitation may be provided if required. If skin is affected with the liquid, remove the clothing & wash the affected area with plenty of water. Seek medical aid.

Not availableSPILLS Steps to be taken

Waste Disposal Method

Shut off leaks if without risk. Warn everybody that air mixture is explosive.Allow gas to burn under control

7. ADDITIONAL INFORMATION/ REFERENCES

Avoid contact with oxidisers. Olefinic impurities may lead to narcotic effect or it may act as a simple asphyxiant. A very dangerous hazard when exposed to heat or flame. If fire is big, keep surrounding areas cool by spraying water.

8. MANUFACTURER/ SUPPLIERS DATA

Name of firm :Mailing Address :

9. DISCLAIMER

Information contained in this material safety data sheet is believed to be reliable but no representation, guarantee or warranties of any kind are made as to its accuracy, suitability for a particular application or results to be obtained from them.

_________________________________________________________________________


Material Safety Data Sheet

NATURAL GAS

A. Product Identification

Synonyms: Residue gas; raw gasChemical Name: Natural gasChemical Family: MixtureChemical Formula: MixtureCAS Reg. No.: 8006-14-2Product No.: Not EstablishedProduct and/or Components Entered on EPA's TSCA Inventory: YESThis product is in U.S. commerce, and is listed in the Toxic SubstancesControl Act (TSCA) Inventory of Chemicals; hence, it may be subject to applicable TSCA provisions and restrictions.

B. Components

Ingredients CAS Number % By Wt OSHAPEL ACGIHTLV

Methane 74-82-8 60-95 NE Simple AsphyxiantEthane 74-84-0 2-15 NE Simple AsphyxiantPropane 74-98-6 1-10 1000 ppm Simple AsphyxiantButane 109-97-8 0-4 800 ppm 800 ppmIsobutane 75-28-5 0-4 NE NENitrogen 7727-37-9 0-15 NE NECarbon dioxide 124-38-9 0-5 10000 ppm 5000 ppmPentanes plus, includes Various

0-8 NE NE

Pentane 109-66-0 NE 600 ppm 600 ppmIsopentane 78-78-4 NE NE NEHexane 110-54-3 NE 50 ppm 50 ppmIsohexane 107-83-5 NE 500 ppm 500 ppmHydrogen sulfide 7783-06-4 0-30 10 ppm 10 ppm

Normal composition ranges are shown. Exceptions may occur which would invalidate data on this form.

C. Personal Protection Information

Ventilation: Use adequate ventilation to control exposure below recommended levels. Respiratory Protection: For concentrations exceeding the recommended level, use NIOSH/MSHA approved air purifying respirator. If conditions immediately dangerous to life or health exist, use NIOSH/MSHA self contained breathing apparatus (SCBA). Eye Protection: Use chemical goggles. Skin Protection: No special garments required. Avoid unnecessary skin contamination with material.

_____________________________________________________________________

On-Site Emergency Management Plan & Disaster Control Measures of Maruti Suzuki India Ltd., Gurgaon 13.26NOTE: Personal protection information shown in Section C is based upon general information as to normal uses and conditions. Where special or unusual uses or conditions exist, it is suggested that the expert assistance of an industrial hygienist or other qualified professional be sought.

D. Handling and Storage Precautions

Proper personal protective equipment must be used when handling this chemical. Do not get in eyes, on skin or on clothing. Do not breathe vapor, mist, fume or dust. May be harmful. Wash thoroughly after handling. Launder contaminated clothing before reuse. Use only with adequate ventilation. Store in tightly closed container. Store in well-ventilated area. Keep away from heat sparks and flame. Bond and ground during transfer.

E. Reactivity Data

Stability: StableConditions to Avoid: Not EstablishedIncompatibility (Materials to Avoid): Oxygen and strong oxidizing materialsHazardous Polymerization: Will Not OccurConditions to Avoid: Not EstablishedHazardous Decomposition Products: Carbon oxides and various hydrocarbons formed when burned. Sulfur oxides may be formed if hydrogen sulfide is present.

F. Health Hazard Data

Recommended Exposure Limits:

See Section B.

Acute Effects of Overexposure:

Eye: May cause irritation including pain, blurred vision, redness, tearing and superficial corneal turbidity.

Skin: May cause slight irritation.

Inhalation: Toxic by this route of exposure. May cause nausea, diarrhea, loss of appetite, dizziness, disorientation, headache, excitation, rapid respiration, drowsiness, labored breathing, anesthesia and other central nervous system effects. Hydrogen sulfide may cause lung paralysis and asphyxiation. Extreme overexposure may cause rapid unconsciousness and respiratory arrest.

Ingestion: Not Applicable.

_________________________________________________________________________


Subchronic and Chronic Effects of Overexposure:

Exposure to 1000 ppm propane for eight hours a day, five days a week, for approximately two weeks produced no abnormal reactions, including cardiac, pulmonary, and neurologic functions in humans.

Chronic high level n-hexane exposure damages the nervous system initially producing a lack of feeling in the extremities and possibly progressing to a more severe nerve damage. Inhalation of high levels (1000 and 5000 ppm) of n-hexane has produced testicular damage in rats. Mice exposed to the same dose levels showed no testicular effects. Carbon dioxide exposure may cause acidosis and imbalance of electrolytes in the blood.

Other Health Effects:

A Toxicity Study Summary for Methane, Pure Grade, is available upon request.

The odor of hydrogen sulfide may not be recognized after prolonged inhalation due to paralysis of the sense of smell. Effects from inhaling the fume may lead to chronic bronchitis, respiratory irritation, increased loss of pulmonary function, and tearing of the eyes.

Health Hazard Categories:

Animal Human Animal Human

Known Carcinogen ___ ___ Toxic _X_ ___Suspect Carcinogen ___ ___ Corrosive ___ ___Mutagen ___ ___ Irritant ___ ___Teratogen ___ ___ Target Organ Toxin _X_ _X_Allergic Sensitizer ___ ___ Specify - Nerve Toxin; Blood ToxinHighly Toxic ___ ___ Lung-Simple Asphyxiant

First Aid and Emergency Procedures:

Eye: Flush eyes with running water for at least fifteen minutes. If irritation or adverse symptoms develop, seek medical attention.

Skin: Wash skin with soap and water for at least fifteen minutes. If irritation or adverse symptoms develop, seek medical attention.

Inhalation: Immediately remove from exposure. If breathing is difficult, give oxygen. If breathing ceases, administer artificial respiration followed by oxygen. Seek immediate medical attention. Ingestion: If illness or adverse symptoms develop, seek medical attention.

_________________________________________________________________________


G. Physical Data

Appearance: Colorless gas

Odor: Mild to rotten egg odor, if hydrogen sulfide is present.

Boiling Point: -285F (-161C)(Estimate)

Vapor Pressure: Not Applicable

Vapor Density (Air = 1): 0.8 (Estimate)

Solubility in Water: Negligible

Specific Gravity (H2O = 1): 0.5 (Estimate)

Percent Volatile by Volume: Not Applicable

Evaporation Rate (Butyl Acetate = 1): Not Applicable

Viscosity: Not Applicable

H. Fire and Explosion Data

Flash Point (Method Used): -292F (-180C) (Estimate)

Flammable Limits (% by Volume in Air): LEL – 5 UEL - 15.8

Fire Extinguishing Media: Dry chemical, foam or carbon dioxide (CO2)

Special Fire Fighting Procedures: Stop flow of gas. If possible, let fire burn until flow of gas can be shut off. Evacuate area of all unnecessary personnel. Wear appropriate safety equipment for fire conditions including NIOSH/MSHA self-contained breathing apparatus (SCBA) and protective equipment and garments described in Section C. Water fog or spray may be used to cool exposed equipment and containers.

Fire and Explosion Hazards: Very dangerous when exposed to heater flame. Containers may explode violently in the heat of a fire. Vapors may travel to a source of ignition and flash back. If hydrogen sulfide is present, respiratory equipment specified above must be used.

I. Spill, Leak and Disposal Procedures

Precautions required if Material is Released or Spilled: Evacuate area of all unnecessary personnel. Wear protective equipment and/or garments described in Section C if exposure conditions warrant. Shut off source, if possible and contain spill. Protect from ignition. Keep out of water sources and sewers. Absorb in a dry, inert material (sand, clay, etc). Transfer equipment. Waste Disposal (Insure Conformity with all Applicable Disposal Regulations): Incinerate or place in permitted waste management facility.

_________________________________________________________________________


J. DOT Transportation

Shipping Name: Natural gas, compressedHazard Class: 2.1 (Flammable gas)ID Number: UN 1971Packing Group: Not ApplicableMarking: Natural gas, compressed/UN 1971Label: Flammable gasPlacard: Flammable gas/1971Hazardous Substance/RQ: Not ApplicableShipping Description: Natural gas, compressed, 2.1 (Flammable gas), UN 1971Packaging References: 49 CFR 173.302 and 173.306

K. RCRA Classification - Unadulterated Product as a

Waste

Ignitable (D001)Prior to disposal, consult your environmental contact to determine if TCLP (Toxicity Characteristic Leaching Procedure, EPA Test Method 1311) is required

Equipment

Contact immediate supervisor for specific instructions before work is initiated. Wear protective equipment and/or garments described in Section C if conditions warrant.

_________________________________________________________________________



IDENTITY OF MATERIAL : DIESEL

Product Name

: Diesel oil, Gas oil. Lube Class : Red – FLAMMABLE LIQUID.

UN No. 1202

Trade Name

: HSD CAS No.

Formula : Complex mixture of Hydrocarbons.

HAZCHEM Code : 3Y

PHYSICAL AND CHEMICAL PROPERTIES :

Physical state

: Liquid Boiling point / Range C

: 150-400 Vapour Pressure : < 1

Appearance : Light brown Melting / Freezing pt. C

: 18 to 40 (at 38deg C mm Hg)

Odour : Diesel Vapour density (Air =1)

: 3 to 5 Evaporation rate

Solubility : Insoluble (30 ppm) Specific Gravity 20 C

: 0.81 to 0.91

(at 30 deg C)

In water : Dyn. Viscocity. : Heat of vaporization : 2.71 + 05

Calorific Value

: 4.34E + 07 (PAS 30 deg C) : (J/Kg)

(J/KG) : Molecular weight Sp heat hq J/Kg : 2.343E + 03

FIRE AND EXPLOSIVE HAZARDS DATA :

Explosivity : Moderate Auto lgnition Temp C

: 256.6 Flash Point, CCC/OC : 32 to 96

Flammability : Moderate Explosive limits. : 0.7-5 Burning Rate : 4 mm / min

Extingsh Media : Foam, CO2, DCP, Water may be ineffective and cause fire to spread may be used to used to cool fire exposed.

:

Containers : :Special Procedures

: :

Unusual Hazards

: Flashback may occur along vapour trail

:

_________________________________________________________________________


REACTIVE HAZARDS :

Stability : Stable Conditions to avoid

: Keep away from heat and open flame.

Hazardous Poly

: Conditions to avoid

:

Incompatibility : Oxidising agents. :Hazardous Combustion / Decomposition products

: Toxic gases / vapours (CO)

:

HEALTH HAZARD DATA :

Entry Route : :TLV, PPM mg/cu.m

: STEL, PPM mg/cu.m : 10 mg/ m³ Odour threshold : 0.1

PEL, PPM mg/cu.m

: LD50 oral,Rat g/kg : 28 LD50 Rabbit g/kg : 0.2

Sign / Symptoms of Exposure.

: Delayed Toxicity : LDLo, Mammal.

INHALATION : Dizziness, headache, ASPIRATION – developing potential fatal chemical pneumonitis.

INGESTION : Nausea, vomiting.CONTACT : Skin-irritation , Eyes –irritation, Dermatitis may result on prolonged contact.Emergency Treatment.

: ( IMMEDIATE MEDICAL ATTENTION REQUIRED)

INHALATION : Remove victim to fresh air, give artificial respiration if necessary. If unconscious but breathing place in the unconscious (recovery) position. Give external cardiac massage if necessary.

INGESTION : Do not induce vomiting.CONTACT : Remove contaminated clothing and wash affected part (skin / eyes) with plenty

of water.

HAZARD SPECIFICATION:

NFPA RATING

Health : 0 Flammability: 2 Material Factor: 10Stability : 0 Special :

KNOWN HAZARDS:

Combustible liquid Flammable material Flammable liquid Pyrophoric materialExplosive material Unstable material Water recative matOxydizer Organic peroxide Corrosive materialCompressed gas. Irritant Sensitizer.Carcinogen. Mutagen Others.

_________________________________________________________________________

On-Site Emergency Management Plan & Disaster Control Measures of Maruti Suzuki India Ltd., Gurgaon 13.32SAFE USAGE DATA :

VENTILATION : Adequate ventilation.PROTECTIVE EQUIP :EYES : Goggles face shields.RESPIRATORY : Self contained breathing apparatus for containment / cleanup

operations.GLOVES : Rubber.CLOTHING : Rubber.OTHERS :

RECAUTIONS:

Handling / Storage.

Diesel should be stored in well ventilated properly labeled and approved containers. Sniffing siphoning and use as a solvent and cleaning agent should be avoided. Do not transfer to unlabeled, unsuitable or incorrectly labeled containers. All containers should be kept out of reach of children and kept fully closed when not in use. Cleaning and inspection / maintenance of storage tanks should be done according to proper procedures and precautions (work permit system gas freeing of tanks, using lifeline and wearing air supplied breathing apparatus.)

Others

EMERGENCY RESPONSE DATA:

Release / Sill / Waste Disposal.

Avoid spillages should they occur sand or earth are useful means of containment and absorption.

ADDITIONAL INFO :

Gastric lavage should be done after endotracheal intubation, in view of risk of aspiration which can cause chemical pneumonitis for which antibiotic and corticosteroid therapy may be indicated.

MANUFACTURER / SUPPLIER :

Name & Address:Telephone No. :Contact person :

REF.: Environment Canada, Chemical hazards of the work place : OPHG for Chemical Hazards : CONCAWE report 2/83.

_________________________________________________________________________



NAME OF PRODUCT / CHEMICAL : Fuel Oil

IDENTITY OF MATERIAL :

Product Name Fuel oil, Residual fuel oils, Bunker fuel oils.

UN No. 1270

Label / Class Not regulatedTrade name FO CAS No.

Formula Complex mixture of Hydrocarbons.

HAZCHEM Code 3Y*E

PHYSICAL AND CHEMICAL PROPERTIES

Physical State Liquid Boiling Point / Range , deg. C

185-500 Vapor Pressure at 20 deg. C, mm Hg.

<1mm Hg.20 C(approx)Appearance Brown to Black Melting / Freezing Point

, deg. C29 to 10(at 38 deg C, mm Hg.)

Odor Diesel fuel Vapor Density (Air =1) 3 to 5 Evaporation Rate at 30 deg. CSolubility in

WaterInsoluble Specific Gravity , 15.5

deg. C0.9 to 1.05

Calorific Value (Kcal / Kg.)

4.34E+07 Dyn. Viscosity (PA.S 30 deg. C)

Heat of Vaporisation , Kcal / Kg.

2.9E+05

Molecular Weight. Sp. Hea liq. J/KG

1.9+03

FIRE AND EXPLOSIVE DATA

Explosivity Auto Ignition Temp. deg. C

263 to 407 Flash Point ,C, CC/OC

66 C and above

Flammability Moderate Explosive Limits , % 1 to 5 Burning Rate 4mm/min

Extinguishing Media

Foam, CO2, DCP. Water may be ineffective and cause fire to spread. May be used to cool fire exposed containers.

Special Procedures

If a leak or spill has not ignited, use water spray to disperse the vapours and to provide for men attempting to stop a leak. Water spray may be used to flush spills away from exposure area.

Unusual Hazards

REACTIVE HAZARDS

Stability Stable Conditions to Avoid Keep away from heat and open flame.

Hazardous Poly Condition to Avoid

Incompatibility Oxidising agents.

Hazardous Combustion / Decomposition Products

Toxic gases/vapours (CO).

____________________________________________________________________________


HEALTH HAZARD DATA

Entry Route Inhalation/Skin absorption

TLV, PPM, mg. / cu. m.

5 mg/m3(inhalation)

STEL , PPM , mg. / cu. m.

10 mg/m3 Odor Threshold , PPM

0.1

PEL ,PPM , mg. / cu. m.

LD50 oral , Rat g. / kg.

LDLo . Human , mg. / kg.

Sign / Symptoms Of Exposure Delayed Toxicity

Inhalation Dizziness, headache

Ingestion Nausea. vomiting.

Contact Skin-irritation; eyes-irritation. Dermatitis may result on prolonged contact.

Emergency Treatment ( Immediate Medical Attention Required )

Inhalation Remove victim to fresh air; give artificial respiration if necessary. if unconscious but breathing place in the unconscious (recovery) position. Give external cardiac massage if necessary.

Ingestion Do not induce vomiting as it may lead to chemical pneumonitis.

Contact Remove contaminated clothing and wash affected part (skin/eyes) with plenty of water, kerosene/gasoline should never be used.

HAZARD SPECIFICATION

NFPA Rating

Health 0 Flammability

2 Material factor

10

Stability 0 Special

KNOWN HAZARDS

CombustibleLiquid

Combustible liquid Flammable Material

Flammable liquid

Pyrophoric material

Explosive Material

Unstable Material

Water reactive material

Oxydiser Organic Peroxide

Corrosive material

Compressed gas

Irritant Sensitizer

Carcinogen Mutagen Other

_________________________________________________________________________


SAFE USAGE DATA PRECAUTIONS

Ventilation

Handlingand Storage

Fuel oil should be stored in well ventilated, properly labeled and approved containers.

Protective Equipment

Eyes Goggles/face shields

RespiratoryGloves neoprene, butyl

rubberClothing OthersOthers

EMERGENCY RESPONSE DATA

Release / Spill

Avoid spillages. Should they occur, sand or earth are useful means of containment and absorption.

Waste Disposal

ADDITIONAL INFORMATIONGastric lavage should be done after endotracheal intubation, in view of risk aspiration which can cause chemical preumonitis for which antibiotic and corticosteroid therapy may be indicated.

Manufacturer / SupplierName:Address:Telephone No.:Contact person :

_________________________________________________________________________


HYDROCHLORIC ACID, 33 - 40%

1. Product Identification

Synonyms: Muriatic acid; hydrogen chloride, aqueous CAS No.: 7647-01-0 Molecular Weight: 36.46 Chemical Formula: HCl Product Codes:

2. Composition/Information on Ingredients

Ingredient CAS No Percent Hazardous

Hydrogen Chloride 7647-01-0 33 - 40% Yes Water 7732-18-5 60 - 67% No

3. Hazards Identification

Emergency Overview

POISON! DANGER! CORROSIVE. LIQUID AND MIST CAUSE SEVERE BURNS TO ALL BODY TISSUE. MAY BE FATAL IF SWALLOWED OR INHALED. INHALATION MAY CAUSE LUNG DAMAGE

Health Rating: 3 - Severe (Poison)Flammability Rating: 0 – NoneReactivity Rating: 2 - Moderate Contact Rating: 3 - Severe (Corrosive)Lab Protective Equip: GOGGLES & SHIELD; LAB COAT & APRON; VENT HOOD; PROPER GLOVES Storage Color Code: White (Corrosive)

Potential Health Effects

Inhalation: Corrosive! Inhalation of vapors can cause coughing, choking, inflammation of the nose, throat, and upper respiratory tract, and in severe cases, pulmonary edema, circulatory failure, and death.

Ingestion: Corrosive! Swallowing hydrochloric acid can cause immediate pain and burns of the mouth, throat, esophagus and gastrointestinal tract. May cause nausea, vomiting, and diarrhea. Swallowing may be fatal.

Skin Contact: Corrosive! Can cause redness, pain, and severe skin burns. Concentrated solutions cause deep ulcers and discolor skin.

Eye Contact: Corrosive! Vapors are irritating and may cause damage to the eyes. Contact may cause severe burns and permanent eye damage.

_________________________________________________________________________

On-Site Emergency Management Plan & Disaster Control Measures of Maruti Suzuki India Ltd., Gurgaon 13.37Chronic Exposure: Long-term exposure to concentrated vapors may cause erosion of teeth. Long term exposures seldom occur due to the corrosive properties of the acid.

Aggravation of Pre-existing Conditions: Persons with pre-existing skin disorders or eye disease may be more susceptible to the effects of this substance.

4. First Aid Measures

Inhalation: Remove to fresh air. If not breathing, give artificial respiration. If breathing is difficult, give oxygen. Get medical attention immediately.

Ingestion: DO NOT INDUCE VOMITING! Give large quantities of water or milk if available. Never give anything by mouth to an unconscious person. Get medical attention immediately. Skin Contact: In case of contact, immediately flush skin with plenty of water for at least 15 minutes while removing contaminated clothing and shoes. Wash clothing before reuse. Thoroughly clean shoes before reuse. Get medical attention immediately.

Eye Contact: Immediately flush eyes with plenty of water for at least 15 minutes, lifting lower and upper eyelids occasionally. Get medical attention immediately.

5. Fire Fighting Measures

Fire: Extreme heat or contact with metals can release flammable hydrogen gas. Explosion: Not considered to be an explosion hazard. Fire Extinguishing Media: If involved in a fire, use water spray. Neutralize with soda ash or slaked lime. Special Information: In the event of a fire, wear full protective clothing and NIOSH-approved self-contained breathing apparatus with full facepiece operated in the pressure demand or other positive pressure mode. Structural firefighter's protective clothing is ineffective for fires involving hydrochloric acid. Stay away from ends of tanks. Cool tanks with water spray until well after fire is out.

6. Accidental Release Measures

Ventilate area of leak or spill. Wear appropriate personal protective equipment as specified in Section 8. Isolate hazard area. Keep unnecessary and unprotected personnel from entering. Contain and recover liquid when possible. Neutralize with alkaline material (soda ash, lime), then absorb with an inert material (e. g., vermiculite, dry sand, earth), and place in a chemical waste container. Do not use combustible materials, such as saw dust. Do not flush to sewer!

_________________________________________________________________________


7. Handling and Storage

Store in a cool, dry, ventilated storage area with acid resistant floors and good drainage. Protect from physical damage. Keep out of direct sunlight and away from heat, water, and incompatible materials. Do not wash out container and use it for other purposes. When diluting, the acid should always be added slowly to water and in small amounts. Never use hot water and never add water to the acid. Water added to acid can cause uncontrolled boiling and splashing. When opening metal containers, use non-sparking tools because of the possibility of hydrogen gas being present. Containers of this material may be hazardous when empty since they retain product residues (vapors, liquid); observe all warnings and precautions listed for the product.

8. Exposure Controls/Personal Protection

Airborne Exposure Limits:- OSHA Permissible Exposure Limit (PEL):5 ppm Ceiling-ACGIH Threshold Limit Value (TLV):5 ppm Ceiling Ventilation System: A system of local and/or general exhaust is recommended to keep employee exposures below the Airborne Exposure Limits. Local exhaust ventilation is generally preferred because it can control the emissions of the contaminant at its source, preventing dispersion of it into the general work area. Please refer to the ACGIH document, Industrial Ventilation, A Manual of Recommended Practices, most recent edition, for details.

Personal Respirators (NIOSH Approved): If the exposure limit is exceeded, a full facepiece respirator with an acid gas cartridge may be worn up to 50 times the exposure limit or the maximum use concentration specified by the appropriate regulatory agency or respirator supplier, whichever is lowest. For emergencies or instances where the exposure levels are not known, use a full-facepiece positive-pressure, air-supplied respirator. WARNING: Air purifying respirators do not protect workers in oxygen-deficient atmospheres. Skin Protection: Rubber or neoprene gloves and additional protection including impervious boots, apron, or coveralls, as needed in areas of unusual exposure to prevent skin contact. Eye Protection: Use chemical safety goggles and/or a full face shield where splashing is possible. Maintain eye wash fountain and quick-drench facilities in work area.

9. Physical and Chemical Properties

Appearance: Colorless, fuming liquid. Odor: Pungent odor of hydrogen chloride.

Solubility: Infinite in water with slight evolution of heat.

_________________________________________________________________________


Density: 1.18

pH: For HCL solutions: 0.1 (1.0 N), 1.1 (0.1 N), 2.02 (0.01 N)

%Volatiles by volume @ 21C (70F): 100

Boiling Point: 53C (127F) Azeotrope (20.2%) boils at 109C (228F)

Melting Point: -74C (-101F)

Vapor Density (Air=1): No information found.

Vapor Pressure (mm Hg): 190 @ 25C (77F)

Evaporation Rate (BuAc=1): No information found.

10. Stability and Reactivity

Stability: Stable under ordinary conditions of use and storage. Containers may burst when heated.

Hazardous Decomposition Products: When heated to decomposition, emits toxic hydrogen chloride fumes and will react with water or steam to produce heat and toxic and corrosive fumes. Thermal oxidative decomposition produces toxic chlorine fumes and explosive hydrogen gas.

Hazardous Polymerization: Will not occur.

Incompatibilities: A strong mineral acid, concentrated hydrochloric acid is incompatible with many substances and highly reactive with strong bases, metals, metal oxides, hydroxides, amines, carbonates and other alkaline materials. Incompatible with materials such as cyanides, sulfides, sulfites, and formaldehyde.

Conditions to Avoid: Heat, direct sunlight.

11. Toxicological Information

Inhalation rat LC50: 3124 ppm/1H; oral rabbit LD50: 900 mg/kg (Hydrochloric acid concentrated); investigated as a tumorigen, mutagen, reproductive effector.

12. Ecological Information

Environmental Fate: When released into the soil, this material is not expected to biodegrade. When released into the soil, this material may leach into groundwater. Environmental Toxicity: This material is expected to be toxic to aquatic life.

_________________________________________________________________________


13. Disposal Considerations

Whatever cannot be saved for recovery or recycling should be handled as hazardous waste and sent to a RCRA approved waste facility. Processing, use or contamination of this product may change the waste management options. State and local disposal regulations may differ from federal disposal regulations. Dispose of container and unused contents in accordance with federal, state and local requirements.

14. Transport Information

Domestic (Land, D.O.T.)

Proper Shipping Name: HYDROCHLORIC ACIDHazard Class: 8UN/NA: UN1789

International (Water, I.M.O.)

Proper Shipping Name: HYDROCHLORIC ACIDHazard Class: 8 UN/NA: UN1789

15. Other Information

NFPA Ratings: Health: 3 Flammability: 0 Reactivity: 0

Label Hazard Warning: POISON! DANGER! CORROSIVE. LIQUID AND MIST CAUSE SEVERE BURNS TO ALL BODY TISSUE. MAY BE FATAL IF WALLOWED OR INHALED. INHALATION MAY CAUSE LUNG DAMAGE.

Label Precautions: Do not get in eyes, on skin, or on clothing. Do not breathe vapor or mist. Use only with adequate ventilation. Wash thoroughly after handling. Store in a tightly closed container. Remove and wash contaminated clothing promptly. Label First Aid: In case of contact, immediately flush eyes or skin with plenty of water for at least 15 minutes while removing contaminated clothing and shoes. Wash clothing before reuse. If swallowed, DO NOT INDUCE VOMITING. Give large quantities of water. Never give anything by mouth to an unconscious person. If inhaled, remove to fresh air. If not breathing, give artificial respiration. If breathing is difficult, give oxygen. In all cases get medical attention immediately.

Product Use: Laboratory Reagent.

DISCLAIMER:

Qualigens Fine Chemicals (QFC) provides this information which is commonly known and generally available in respect of this product; but makes no representation as to its comprehensiveness or accuracy. This information is given only as a guide to the appropriate

_________________________________________________________________________

On-Site Emergency Management Plan & Disaster Control Measures of Maruti Suzuki India Ltd., Gurgaon 13.41precautionary handling of the material by a trained person. Persons receiving the information must use their judgement in determining its appropriateness for a particular purpose. QFC makes no representations or warranties, either express or implied, including without limitations any warranties of merchantability, fitness for a particular purpose with respect to the information given herein or the product to which the information refers. Accordingly, QFC will not be responsible for damages resulting from use of or reliance upon this information.

MSDS PAINTS

1. Chemical Product and Company Identification:-

Product name: Common Met B/C Bronze MistProduct code:- 1010931(2933/11143)Poisonous and Deleterious Substances Control Law: N.AP.Type :-Acrylic resin coating Use : Automobile paint Company name: Goodlass Nerolac Paints LtdAddress: G K Marg,lower Parel,Mumbai 400013Responsible department: R&D Automotive Paints DivisionPerson in charge (prepared by):Phone number: 022-24934001 & 011-26819000 Fax number: 022-24935742Emergency contact: 022-24934001 & 011-26819000

2. Composition Information on Ingredients

Component and Concentration of Hazardous Substance

CHEMICAL NAME CAS NO. % Wt PRTRMineral Spirit 1 TO 5Petroleum Naphtha H 64742-94-5 1 TO 4

Toluene 108-88-3 10.8 227Xylene 1330-20-7 3.2 63Ethyl Benzene 100-41-4 2.5 40 Methanol 67-56-1 1 TO 4Butanol 71-36-3 2TO 6Ethyl Acetate 141-78-6 3 to 6Formaldehyde 50-00-0 0.1TO 1

3. Hazardous Identification

Classification:- Flammable liquid - Substance of acute toxicity others hazardous substance

Comments on Hazard: - Extremely flammable liquid .May cause explosion when its vapour becomes dense.

- May damage health

_________________________________________________________________________


Contains substance that is suspected of carcinogenic effect

Contains substance that may cause allergenic sensitizing effect

May cause organic solvent toxication–

4. First Aid Measures

In case of inhalation: If disorder occurs for inhalation of vapour or gas, remove to immediately to Fresh Air & rest with keeping warm. Perform artificial respiration if breathing get irregular or stops. Don’t make swallow vomit. If disorder occurs for inhalation of vapour or gas, remove to fresh air,& immediately consult physician with “MSDS”. In case of contact with skin: Wipe quickly clinging matter with clean cloth. Flush with plenty of Water & soap. Don’t use solvent & thinner. In case of entry into eye: Flush with plenty of water for15 minutes or more. Wash Sufficiently the back of eye lids. Consult physician with ‘MSDS’ As soon as possible.

In case of ingestion If one swallows accidentally, immediately rest & consult physician with MSDS Avoid forcing to vomit. Do not make swallow vomit. Avoid forcing to vomit without physician’s instructions.’

5. Fire Fighting Measures

Effective extinguishing media: 1] Carbon dioxide & foam type extinguishers.

2] Dry chemical powder type extinguisher . Fire Fighting Instructions:-

- Wear proper protectors(heat resistance clothing) - Remove immediately flammable matter.- Use specified extinguishing.- Water to cool, when sealed container is exposed to high temperature.- Distinguish to leeward. - Avoid using water for extinguishing fire.

6. Accidental Release Measures:-

- Wear proper protectors (gloves,respirator,safety, goggles,apron etc.)- Recollect leak in container & keep in safety place with the container closed.- Dispose of waste or clinging matter according to related regulations.- Remove immediately ignition source or heat source & other flammable matters.- Furnish with extinguisher proper for accidental fire.- Recollect with tool of non-spark material- Recollect by absorbing with dry sand or soil or other nonflammable matter. Prevent from flowing out by banking if large in volume.- Take precautions so as not to pollute rivers ,lakes etc.

7. Handling and storage

Handling:-

- Handling in well ventilated area & close tightly container with closer necessarily during & after use.

_________________________________________________________________________

On-Site Emergency Management Plan & Disaster Control Measures of Maruti Suzuki India Ltd., Gurgaon 13.43- Close tightly container with closer necessarily during & after use.- Take away from open flame,spark or heat –source.- Ground equipment for the prevention of static electricity accident because of generating

easily static electricity & use electric appliance or apparatus of explosion proof type because of containing organic solvents.

- Use handtool of spark proof type.- Keep dirty rag, paint sludge & paint dust soaking in water before disposing of.- Wear antistatic suits & shoes while working- Wear proper protectors to avoid contact of skin ,eyes & mucosa & of clothing.- Wash thoroughly hand & face after handling, Avoid bringing contaminated protectors in

any place where person stays.- Install proper local ventilator & wear proper protectors in closed space - Don’t let a person who has ever suffered allergy handle- Perform operations including applications according to “Foul Smell Control Law” because

paint products & materials & their waste are specified as a foul smell material to be regulated in the law

Storage:-

- Avoid direct sunlight- Store in good ventilation- Store with keeping away from ignition or heat source.

8. Exposure Controls and Personal Protection

Protection facility and equipment:- Used explosion proof type equipment.

- Install proper exhaust to prevent concentrating of vapor. - Ground equipment for fluid transfer,pumping & stirring.- Use equipment devised so that heat or ignition source can not be placed In the

neighborhood of handling place.- In indoor application, use automatic applicator or install equipment or local exhauster to

avoid direct exposure to spray mist.- In application in closed space or the like (tanks),install equipment which Can sufficiently

ventilate even its bottom.

Protectors:

Eye protector: Wear safety goggles

Respiratory system protector: 1] Wear gas mask for organic gas.2]Wear air mask in closed space.

Hand protector: Wear gloves impervious to organic solvent & chemical.

Skin and body protector: Wear appropriate protective clothing.

Others Protector:- Wear electricity conductive shoes in electrostatic application.

_________________________________________________________________________


9. Physical and chemical properties

Physical condition:

Shape: Liquid Odour Oragnic solvent smellColor: Brown pH: N,A

Temperatures that change the physical state

Boiling point 73-146°C Ignition point 370°CFlash point 13°C Density 1.00g/cm3

Explosion property N.A

Explosion limits: Lower limit : 1.1 % Upper limit: 11.2 %

Steam pressure: 13335/ Pa (27°C )

10. Stability and reactivity

Reactivity & Stability Condition (Temperature, Light etc) – Does not react under normal conditions.

Hazardous Reaction:- N.AV

Product Decomposition/Dangerous Substance Generation:- N.AV

Other Reactivity Information:- N.AV

Additional Information:-Avoid leaving cloth, paper ,brush or roller which contains the paint or its dust to accumulate or to be made round.

11. Toxicological Information:-

No Components name CC ACGIH (TLV-TWA) RAC LD 50 (mg/kg) other hazards

1 Mineral Spirit 100P

2 Toluene 50P 50P 636 mouse S1

3 Petroleum Naphtha H 100P

4 Xylene 100P 100P 4300 mouse

5 Ethyl Benzene 100P 2B 3500 mouse

6 Methanol 200P 200P 6628 mouse S1

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7 n-Butanol 25P 790 mouse

8 Ethyl Acetate 400P 400P 5620 mouse

9 Formaldehyde 2A 100 mouse CR-SD-AS

*Sign:- P-ppm mg/m3 C.C:- Control Criteria, SD:- Skin Damage, CR:-Corrosive, FT:- Fish Toxicity, ACGIH:- American Conference Of Governmental Industrial Hygienists AS: Allergenic Sensitizing Effect, IARC:- International Agency for Research on Cancer ,SI: Skin Irritation ,TE: Teratogenic Effect, LD50:-mouth (oral-rat) skin(rabbit) RE:- Effect on the Reproductive System,MU:- Mutagenic Effect, EI:- Eye irrtation Sit:- Skin itch, Additional Component Toxicity Information: - NAV, Product Toxicity Information:- The Toxic property of final product is untested.

12. Ecological Information

Take cautions in handling because it may contaminate environment when it leaks or spills or it is dumped .Especially ,take cautions for product or rinsing water not to flow into the ground, river or ditch.

13. Disposal Considerations:-

- Let authorized industrial waste handling agent dispose of paint waste, container waste etc, by making service agreement.

- Don’t dispose of waste water after cleaning container ,equipment , tool, etc into the ground & drainage ditch without treatment.

- Burn up paint waste,additive waste ,etc,little by little using incineration of open type with them absorbed in diatomaceous earth.

14. Transport Information:-

General:- Accord to the description in “Prevention in Handling” & “precautions in Storing,” Make sure that container does not leak & be sure to prevent it from collapsing by loading with it so that it may not overturn or fall down or sustain damage.

Land Transportation: - Accord to each transportation method specified in “Fire Service Law” “Industrial Safety & Health Law”, when applicable to any of them.

Maritime Transportation:- Accord to requirements specified in :the vessels Safety Law(Ship Safety Act)

Air Transportation:-Accord to requirement specified in “ the Aviation act’

15. Regulatory Information Relevant Regulations

16. Other information N.A.

_________________________________________________________________________



SECTION I : MATERIAL IDENTIFICATION & USEMATERIAL NAME : Thinner 90 IDENTIFIER/ CODE NO. : 53153898MANUFACTURER’S NAME :BASF Coatings Pvt. Ltd.STREET ADDRESS :147, Mumbai-Pune Road,PimpriCITY : Pune STATE : MaharashtraPOSTAL CODE : 411018EMERGENCY TELEPHONE NO. 27464081

SUPPLIER’S NAME :BASF Coatings Pvt. Ltd.STREET ADDRESS :147, Mumbai-Pune Road,PimpriCITY : Pune STATE : MaharashtraPOSTAL CODE : 411018EMERGENCY TELEPHONE NO. 27464081

CHEMICAL NAME : Thinner TRADE NAME & SYNONYMS: Thinner 90 PRODUCT USE: Paint dilution

SECTION II : HAZARDOUS INGREDIENTS OF MATERIALHAZARDOUS INGRDIENTS

APPROXIMATE CONCENTRATION%

C.A.S./UNION NO.

LD 50(SPECIFY SPECIES & ROUTES)

LC 50(SPECIFY SPECIES & ROUTES)

Aromatic Hydrocarbons 10-20 1330 – 20 -7

4300 mg / Kg Not available

Aliphatic Esters 80-90 123-86-4112-07-2

14000mg/Kg6550mg/Kg

Not available

Aliphatic alcohols

00-10 71-36-3 Oral- rat 790 mg /Kg

Not available

SECTION III : PHYSICAL DATA OF MATERIAL

PHYSICAL STATE :Liquid

ODOUR & APPEARANCE:Sweet, Clear

ODOUR THRESHOLD :0.05 ppm

SPECIFIC GRAVITY :0.86 +/- 0.03 @ 25C

VAPOUR PRESSURE : 6.72 mm Hg at 21C

VAPOUR DENSITY :Data not available

EVAPORATION RATE:Data not available

BOILING POINT C:>120

FREEZING POINTC:Data not available

SOLUBILITY IN WATER ( 20 C) :Immiscible

pH:Around 7

DENSITY (gm/l):0.86 +/- 0.03 @ 25C

COEFFICIENT OF WATER /OIL DISTRIBUTION:Not Applicable

SECTION IV : FIRE AND EXPLOSION HAZARD OF MATERIALFLAMMABILITY YES-NO IF YES UNDER WHAT CONDITION : Flammable , In presence of open flame, spark or other source of ignition

MEANS OF EXTINCTION : 1.Foam 2. Carbon Dioxide

FLASH POINT C & METHOD Above 30 C (Closed cup)

UPPER EXPLOSIVE LEVEL(%BY VOLUME ) 7.5 app.

LOWER EXPLOSIVE LEVEL (% BY VOLUME) 1.4 app.

AUTOIGNITION TEMP.C > 360

TDG FLAMMABILITY:Classification 185-500

HAZARDOUS COMBUSTION PRODUCTS : Emits acrid smoke & irritating fumes

SENSITIVITY TO CHEMICAL IMPACTNo

SENSITIVITY TO STATIC DISCHARGEStable

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SECTION V : REACTIVITY DATACHEMICAL STABILITY : YES/NO YesIF NO UNDER WHAT CONDITION INCOMPATIBILITY WITH OTHER SUBSTANCES : YES/NO YESIF YES , WHICH ONES : Oxidizing material REACTIVITY UNDER WHAT CONDITIONS : Reacts vigorously with oxidizing substances HAZARDOUS DECOMPOSITION PRODUCTS : Not applicable

SECTION VI : TOXICOLOGICAL PROPERTIES OF MATERIALROUTE OF ENTRY SKIN CONTACT : Irritation SKIN ABSORPTION : Irritation EYE CONTACT : IrritationINHALATION ACUTE : causes coughing INHALATION CHRONIC : Pulmonary edema INGESTION : causes nausea, vomiting, cramps, headache. EFFECTS OF ACUTE EXPOSURE TO MATERIAL ; Same as above EFFECTS OF CHRONIC EXPOSURE TO MATERIAL EXPOSURE LIMIT 100 ppm IRRITANCY OF MATERIAL : Yes SENSTISATION TO MATERIAL:Not Available

CARCINOGENICITY, REPRODUCTIVE EFFECTS , TEROTOGENECITY, MUTAGINICITY : No

SYNERGESTIC MATERIAL: Not Available.SECTION VII : PREVENTIVE MEASURESPERSONAL PROTECTIVE EQUIPMENT

GLOVES : Rubber / Surgical

RESPIRATORY : Face Mask, Lung protector

EYES : Safety Goggle

FOOTWEAR : Safety shoes

CLOTHING : Apron OTHER

ENGINEERING CONTROL ( VENTILATION, ENCLOSED PROCESS ETC.)Adequate ventilation during handling LEAK AND SPILL PROCEDURES: Contain spillage by absorbing on absorbent material WASTE DISPOSAL: Incinerate in controlled mannerHANDLING PROCEDURE AND EQUIPMENT : No specific requirement STORAGE REQUIREMENTS : Store under shed with adequate ventilation & away from source of ignitionSPECIL SHIPPING INFORMATION: Avoid spillage, leakage. Keep away from source of ignition.

SECTION VIII : FIRST AID MEASURESFIRST AID MEASURES :

SKIN CONTACT : Remove contaminated clothes. Clean affected area with soap and plenty of water EYE CONTACT : Flush immediately with plenty of running water for 15 minutes.INGESTION: Seek medical attention. INHALATION: Remove to fresh air immediately. Call Physician.

SOURCES USED: Material Safety Data Sheets - ICMA ADDITIONAL INFORMATION : Nil

SECTION IX : DATE OF PREPARATION OF MATERIAL SAFETY DATA SHEETPREPARED BY : Safety & Environment Dept. TELEPHONE NO. 27464081-2 ext. 225DATE : 2002-08-20 MATERIAL NAME : Thinner 90

SECTION X : DISCLAIMERInformation contained in this Material Safety Data Sheet is believed to be reliable, but no representation, guarantee or warranties of any kind are made as to its accuracy, suitability for a particular application or results to be obtained from them

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Annexure – 21SUMMARY OF RISK ANALYSIS

1. Consequences Analysis for MCLS of 20 M. T. Storage Bullet

(a) Catastrophic Failure

The MCLS in the present case is represented by:Catastrophic failure of one of three storage bullets installed therein due to faulty

safety valve, corroded vessel or overpressure caused by external fire radiations.The storage tank is full to its capacity (20 M. T.) when the catastrophic failure

occurs.The vapour / aerosol cloud formed is twice the adiabatic flash fraction of butane and

propane in the mixture.Butane, Propane is in equal proportion.Storage temperature is 35oC. The vapour /aerosol cloud finds a source of ignition resulting in a Fireball.The BLEVE results in spherical propagation of thermal radiation and blast wave in

the surroundings, which have the potential to cause damage to life and property.

Calculations:

Adiabatic flash fraction of propane at 35oC is 0.36 and for butane is 0.20Therefore mass of propane in the vapour cloud = 10 X 0.36 X 2 = 7.2 M. T. and the mass of butane in the vapour cloud = 10 X 0.2 X 2 = 4 M. T. Therefore, total Mass of LPG in the vapour cloud = 11.2 M. T.

Blast Wave Consequences of BLEVE

The blast wave effect on the surroundings has been determined by the TNT curve overpressure vs scaled distance. By this procedure it is assumed that 1 MT of LPG is equivalent to 0.42 M.T. of TNT in respect of the blast wave impact.

Distance from epicentreScaled Distance =

(0.42 X M) 1/3

The reading radial distance from the LPG vessel ( r ) vs peak overpressure on the target ( P ) are shown in the following table.

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r (M) P (bar)

32 3.0

40 2.0

57 1.0

70 0.7

84 0.5

107 0.3

142 0.2

234 0.1

275 0.08

335 0.06

469 0.04

586 0.03

820 0.02

1340 0.01

Blast Wave Impact in the Surroundings

The effects of blast wave in the surroundings are shown in the following table:

Radial Distance From

Epicentre (m)

Peak overpressure

(bar)

Characteristic Damage

107 0.3 Heavy damage to buildings

and processing equipment

234 0.1 Repairable damage to

buildings and façade

damage to dwellings

476 0.03 Glass damage causing

injury

(b) Thermal Radiation Hazard Range of Fire Ball of 20 M. T. LPG Storage Bullet

As calculated for blast wave consequences the mass of LPG in the explosive range is 11.2 M. T.

The radius of fireball is calculated by the formulaR = 29M1/3

Where R= Radius of fire ball (m)M = Mass pf LPG in explosive range

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The R is found to be 65 mDuration of fireball is calculated by formula

t = 4.5m1/3 = 10 seconds

The radiactive flux incident on a target at a distance r is calculated by:q = E F T

Where q = radiative flux at target (kw/m2) E = Surface Emissive Power (kw/m2)T = Atmospheric transitivity

The T calculated by equation:T = 1 – 0.058 ln rF = View factor

The formula used for calculation of view factor is

R2rF =

(R2 + r2)3/2

Where r is the ground level distance between target and LPG bullet.

Based on the above-described procedure the calculated values are shown in the following table:

R F T q

120 0.199 0.722 38.8

150 0.145 0.709 27.4

170 0.119 0.702 22.5

200 0.091 0.692 17.0

250 0.061 0.680 11.2

300 0.144 0.669 7.9

350 0.033 0.660 5.8

400 0.025 0.652 4.4

450 0.020 0.645 3.5

500 0.016 0.639 2.8

600 0.011 0.629 1.9

700 0.0085 0.620 1.4

The curve r vs q has been plotted on the basis of the above-tabulated readings and depicted in Fig 1. The curve indicated that the thermal radiation flux on a target for the intensity of 4.0 and 12.5 kw/m2 are at a radial distances from the LPG bullets for the BLEVE scenario are 475 and 225 meters respectively. The thermal radiation flux of 4.0 kw/m2 represents burn

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On-Site Emergency Management Plan & Disaster Control Measures of Maruti Suzuki India Ltd., Gurgaon 13.51injury to exposed people whereas 12.5 kw/m2 represents hazard range for property damage. The effects of the thermal radiations in the surroundings can be interpreted from the Table-1. It may be borne in mind that the duration of exposure to the present described BLEVE scenario would be 10 seconds.

(c) Failure of Liquid LPG Discharge Line at the Bottom of the Storage Bullet In the event of failure of the liquid discharge line of the LPG storage bullet the maximum rate at which the liquid can discharge is restricted to the setting of the excess flow valve installed in the line which is about 260 litres per minute. This discharge rate is 2.6 kg/s.

Assuming butane and propane content in the LPG is in the ratio of 1:1, the vapour release would be twice the adiabatic flash fraction of butane and propane at 35oC

Therefore,Propane vapour release rate = 0.936kg/sButane vapour release rate = 0.52kg/s.

As the adiabatic flash fraction of propane and butane at 40oC are 0.36 and 0.2 respectively.

Total Vapour Release Rate 1.456kd/s.

The LPG vapour cloud for the present scenario will disperse along with the wind. For the MCLS the wind velocity has been assumed to 2m/s. It is also assured that the weather category is E which represents the night time.

The maximum distance to the lower explosive limit (x2) from the leak source is calculated from the formula: M 1/g+d

X2=I T u a c t . C L E L

Where m = vapour release rate bg/sU = wind velocity (2m/s)a & b = Constants for calculation of sigma Yg = for continuous sourcect = connection factor for the averaging time for sigma YCLEL = concentration in kg/m3 corresponding to the lower exposure limit.d’ = constant for calculation of a value of sigma Z corrected for the effect of ZO.Xi =maximum distance to the upper explosive limit from the release source can be calculated in analogous way.The explosive limits in air ranges from 2.1 – 9.5% (v/v)

The value of Xi and X2 is found to be 56.m and 23.0m respectively.

The mass of the LPG vapour cloud in the explosive range m ex is calculated by the formula:

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On-Site Emergency Management Plan & Disaster Control Measures of Maruti Suzuki India Ltd., Gurgaon . 13.52

(b + d1) (x2 – xi) m ex =

(b + d1 + I) UThe mass of LPG vapour cloud in the explosive range is found to be 15 kg.

In accordance with the procedure described for the BLEVE scenario the blast effect in terms of r & P are shown in the following table:

r (M) P (bar)

3.5 3.0

4.4 2.0

6.3 1.0

7.7 0.7

9.2 0.5

11.8 0.3

15.7 0.2

25.8 0.1

30.5 0.08

37.0 0.06

52.0 0.04

65.0 0.03

90.0 0.02

148 0.01

The epicentre of the explosive vapour cloud will be at a distance of 26.6 from the leak source in the downward direction. Beyond the distance of 56 – 5m from the leak source in the downward direction will be safe zone in aspect of encountering a source of ignition.

The blast effect for the present scenario are tabulated below:

BLAST WAVE IMPACT IN THE SURROUNDINGS OF EPICENTRE

Radial Distance (m) Peak overpressure Characteristic Damage11.8 0.3 Heavy damage to buildings

and processing equipment

25.8 0.1 Repairable damage to buildings and façade

damage to dwellings65.0 0.03 Glass damage causing

injury

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On-Site Emergency Management Plan & Disaster Control Measures of Maruti Suzuki India Ltd., Gurgaon 13.53The effects of thermal radiation on the surrounding for the present scenario are not going to be significant due to very short duration of exposure (1.1 second)

2. Pool Fire Scenario of HSD Storage

It is assumed that due to failure of a storage tank or its attached pipelines, valves, flange joints the contents are discharge into the dyke. In contact with a source of ignition the vapour in the dyke catches fire. The damage potential of the fire is caused by the thermal emissions in the surroundings.

(a) Consequence Analysis

Cross section area of the dyke is 31.4 X 16.4 m2 . The equivalent diameter of a rectangular pool is calculated by the formula:

4 X A d =

Perimeter of dyke

Where d = equivalent diameter (m) A = Cross section area of dyke m2.

The equivalent diameter of the pool fire is found to be 21.5 m

The rate of burning of pool is calculated by the formula:

dm .00I HC =

dt C l (Tb – Ta) + HVWhere:

Dm/dt = Rate of burning of pool.HC = Heat of combustion of HSD = 423.48 X 106 J/kg

HV = Hat of evaporation of HSD = 3.63 X 105 J/kgCl = Specific heat of liquid = 2.112 X 103 J/kgC6

Tb = Boiling point = 157oC

Ta = Ambient storage tempoerature = 40oC

The rate of burning (dm/dt) isFound to be .178kg/sm2

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The height of the flame is calculated by the formula:

Dm/dt 0.61

L = d X 42 Pa gd

Where Pa = Density of air (kg/m3) l = height of the flame g = Acceleration due to gravity (9.8 m/s2)

The height of the flame is found to be 32.8 m

The average intensity of radiation of the fire (E) is calculated by the formula

0.35 dm/dt. HC x .001 E =

72 (dm/dt) 0.61 + 1

= 70.76 kw/m2

The radiation flux (q) on a target at a distance r from the centre of pool Is calculated by the formula:

q = E F T

F = View Factor

The F for a specific distance from the center of pool is determined from a chart given in the TNO Yellow Book which is based on the value of lf and d.The curve based on the calculated data as shown in the following table has been plotted and depicted in figure 2.In accordance with the publication S. R. 297, by Safety & Reliability Directorate of United Kingdom Atomic Energy Authority entitled “ Thermal radiation hazard ranges from large hydrocarbon pool fires” the emissive power of the large diameter hydrocarbon pool fire is to be taken as 0.3 q due to smoke observation. Thus the value of E is taken as 21 kw/m2

r F T q

12 0.581 .856 10.4

13.2 0.519 .850 9.26

14.3 0.472 .845 8.37

15.4 0.433 .841 7.64

16.5 0.400 .837 7.0

22 0.285 .820 4.9

33 0.166 .797 2.8

44 0.106 .780 1.7

55 0.073 .767 1.2

110 0.019 .727 0.3

_________________________________________________________________________


It is seen that the radiative flux capable of causing secondary fire (12.5 kw/m2) is confined within the pool fire. The curve shown in the fig 2 indicates that the thermal hazard range for the radiation flux of 4.0 kw/ m2 is 24 m from the centre of pool. Thus for such a pool fire scenario the fire fighting is to be done beyond this distance. However, due to higher flash point of HSD (B class petroleum), the probability of occurrence of such fire is very low, as the requirements of the controller of explosives have been implemented for the storage.

3. CNG Pipeline Failure at GAIL Terminal

It is assumed that in the event of failure of the pipeline (16” Diameter) the gas escapes at the maximum supply rate of 5 lac m3 per day, which amounts to be the gas release rate of 3.7 bg/s.

In accordance with procedure for LPG pipeline failure scenario the following input parameters have been obtained:

The maximum distance from the release source for lower explosive limit of methane (5% v/v.) is 119m and for upper explosive limit (15%) is 61 m.

Mass of methane gas in the explosive range is 18 kg

The combustion equation of methane is:CH4 + 2O2 CO2 +2H2O

1 volume of methane combines with 2 volume of oxygen or 10volume of air.

The volume occupied by the 18 kg methane gas = 28m3

Therefore, the volume of gas cloud air mixture in the initial stage would be 11 X 28 = 308 m3 . The characteristic explosive length LO is calculated by the following equation:

Vo Ec 1/3 LO = Pa

Where

EC = Combustion energy of mixture per unit volume which is taken as 3.5 X 106 J/m3

The characteristic explosive length is found to be 22m

_________________________________________________________________________

On-Site Emergency Management Plan & Disaster Control Measures of Maruti Suzuki India Ltd., Gurgaon 13.56Assuming average value of flame front velocity of 160 m/s the peak overpressure P is calculated by the formula:

P = 15 x 10 –2 (r/Lo)-1

The results of the calculation are tabulated below:

R (M) P (bar)4.4 0.756.6 0.508.8 0.375

11.0 0.3013.2 0.2515.4 0.2117.6 0.1922.0 0.1533.0 0.1044.0 0.07566.0 0.0588.0 0.037110 0.03220 0.015

BLAST WAVE IMPACT IN THE SURROUNDINGS

Radial Distance from epicentre (m)

Peak overpressure Characteristic Damage

9.0 0.30 Heavy damage to buildings and processing equipment

33.0 0.10 Repairable damage to buildings and façade damage to dwellings

110 0.03 Glass damage causing injury

The instrumentation and control system would drop the supply of CNG to the GAIL Terminal a soon as the pressure in the line falls. Thus the CNG release scenario will last for a short duration.

It may be noted that the epicentre of the gas closed explosion for the present scenario will be 90m away from the leak source in the downwind direction of the assumed velocity of the wind to be 2m/s.

Failure of 6” CNG Pipe Line from GAIL Terminal to the Plant

For a pipeline failure in accordance with the reference 4 in the bibliography the leakage is assured to be from a hole whose diameter is 20% of the pipeline.

_________________________________________________________________________

On-Site Emergency Management Plan & Disaster Control Measures of Maruti Suzuki India Ltd., Gurgaon 13.57The release is rate of the methane gas was calculated by the formula:

Prm = CFA K 2 K+1 8314 x Tr

M

Where

M = release rate of methane gas

CF = Coefficient of Outflow

A = Cross section area of the outflowOpening = 7.06 cm2

cp sp. Heat at constant pressurek = =

cu sp heat at constant volume

= 1.1Pr = Pressure in the line = 20 bar(g)Tr = Temperature of Gas (313 k)M = Mol. Weight 16 kg/kmol

The CNG release rate is found to be 1.32 kg/s.

Using the earlier described procedure the results obtained for the scenario are: The maximum distance from the release source for lower explosive limit is 63m and for

upper explosive limit is 33m The mass of methane in the explosive range is 9.3 kg. The characteristic explosive length (Lo) is 1.0mThe results are shown in the following table:

r (M) P (bar)

3.6 0.75

5.4 0.50

7.2 0.375

K+1

9.0 0.30

10.8 0.25

13.3 0.21

14.4 0.19

18.0 0.15

27.0 0.10

36.0 0.075

54.0 0.05

72.0 00.037

90.0 0.03

180 0.015

_________________________________________________________________________


BLAST WAVE IMPACT IN THE SURROUNDINGS

Radial Distance from epicentre (m)

Peak overpressure Characteristic Damage

9.0 0.3 Heavy damage to buildings and processing equipment

27.0 0.1 Repairable damage to buildings and façade damage to dwellings

90.0 .03 Glass damage causing injury

4. Thermal Hazard Range of CNG Cloud Explosion

(I) CNG Pipeline Failure of CNG GAIL Terminal

As calculated in the described scenario the amount of gas in the explosion range is 18

kg.

The duration of vapour cloud explosion is calculated by the formula:

t = 1.089 x (m).327

Where t = duration of fireball

m = Mass of fuel in explosive range

t is found to be 2.8 seconds.

The energy released by combustion (k) is calculated by the formula

Hc M.637

K= KJ /s

1.089 x 103

Where Hc = heat of combustion

= 50.11 x 106 J/kg

The value of K is found to be : 290071 KJ/s

The radiation flux I at a distance r from the epicentre is calculated by formula:

K (Xe) T

I =

4 IT r2

Where:

Xe is the fraction of combustion heat emitted as readiation

T = Transmissivity of air path calculated by the formula:

T = 1-0.058 ln r

_________________________________________________________________________


The results are tabulated as follows:

r (m) T I (kw/m2)15 .842 30.217 .835 23.419 .829 18.521 .823 15.023 .818 12.525 .813 10.530 .802 7.240 .786 4.060 .762 1.780 .746 0.94

It is seen from the above table that radial distance from the epicentre of the explosive cloud are 40 m and 23 m from thermal radiation flux of 4.0 kw/m2 and 12.5 kw/m2. The effect of thermal radiation flux can be interpreted from the Table-1. The thermal radiation flux of 4.0 kw/m2 represents the range for burn injury to people whereas 12.5 kw/m2 represents hazard range for property damage, however the duration of exposure is limited to 2-8 seconds only.

(II) Failure of 6” Diameter Pipeline from GAIL Terminal to Plant

Mass of methane in explosive range = 9.3 kg.

The duration of explosive calculated by the formula t = 1.089 m.327 = 2.2 seconds

By the previous described procedure the results are tabulated below:

R (m) T I (kw/m2)12 0.856 31.5

14 0.847 22.916 0.839 17.418 0.832 13.6

18.8 0.830 12.520 0.826 10.922 0.820 9.025 0.813 6.930 0.802 4.732 0.799 4.035 0.744 3.4340 0.768 2.660 0.762 1.1

_________________________________________________________________________


The hazard range from epicentre For Burn injury (4kw/m2) = 32 mFor property damage = 18.8 m

* * *

_________________________________________________________________________


Thermal Hazard Range of BLEVE resulting from catastrophic failure of LPG Bullet

0

5

10

15

20

25

30

35

40

45

0 100 200 300 400 500 600 700 800

Radial Distance from LPG Bullet

The

rmal

Rad

iatio

n F

lux

on T

arge

t (K

W/m

2)

Fig-1

_______________________________________________________________________________________________

On-Site Emergency Management Plan & Disaster Control Measures of Maruti Suzuki India Ltd., Gurgaon

Thermal Hazard Range of HSD Storage Bund Pool Fire

0

2

4

6

8

10

12

0 20 40 60 80 100 120

Radial Distance from LPG Bullet

The

rmal

Rad

iatio

n F

lux

on T

arge

t (K

W/m

2)

Fig-2

__________________________________________________________________________________________________

On-Site Emergency Management Plan & Disaster Control Measures of Maruti Suzuki India Ltd., Gurgaon

Annexure-22

AREA RISK EVALUATION

Towards Location/Name of the Village

Approx. distance from Plant Boundary

Population

KAPASHERA 4 KM 12761

NORTH NAGAL DEWAT 7 KM 13163

DUNDAHERA 3 KM 10626

AYANAGAR 7.5 KM 13925

EAST RAJOKARI 5 KM 12761

GADAI PUR 9 KM 1062

JHARSA 5 KM 21658

SOUTH WAZIRABAD 7.5 KM 4679

NAHARPUR 7.5 KM

DHANWAPUR 8.5 KM 1118

WEST DAULTABAD 7.5 KM 566

CHAKKARPUR 4.5 KM 14216

Note:- The area risk evaluation is under study by EM2 for KB Casting plant approval.

_________________________________________________________________________

On-Site Emergency Management Plan & Disaster Control Measures of Maruti Suzuki India Ltd., Gurgaon 13.62Annexure – 23

Communication Procedure

COMMUNUCATION Note: Clearance for all activities outside

ON WIRELESS plant premises, i.e. to external agencies, ON MOBILE PHONES will be given as per requirement by the

Incident observer

Maintenance Dispensary

Fire Department (Tel 3456/3500)

Shop In-charge / Supervisor

Security Gate

MARG (Mutual Aid Response

Group )

INCIDENT CONTROLLER Site

Controller

EMERGENCY CONTROL CENTRE

Fire & Rescue Team

Security & Vigilance Facilities

Emergency Support Team

Media / Spokes Person

TPT

MP2

Drinks / foodHead count-EMR & area HOD

EM1

RehabilitationCommunication

MPCMP1 EM2 CVLEM3

ON LAND-LINE WHERE POSSIBLE site controller.

Annexure - 24

FORMAT FOR RECORDING TELEPHONE MESSAGES IN ECC

1. Name of the person who telephoned: ________________________________

2. His Telephone No.: ______________________________________________

3. Message: _____________________________________________________________________________________________________________________

____________________________________________________________

4. Message to be conveyed to: _______________________________________

_______________________________________________________________

5. Message conveyed at (Time): _______________________________________

______________________________________________________________________________________________________________________________

Name: ___________________________________ Department: _______________

Signature: ________________ Date: __________________

Time: ___________________

Description of messages

Incoming Outgoing

Time From Description Time To Description

Annexure-25

LIST OF FIRE FIGHTING EQUIPMENT

Details of Fire Protection Systems / Equipments

SN Particulars Remarks

1 CO2 flooding Fire Protection System – Paint Shop-1 1



4 CO2 flooding Fire Protection System – Paint Store-1 1



7 CO2 flooding Fire Protection System – Hot wax coating Assembly-1 1



10 CO2 flooding Fire Protection System – Gas Turbine – 1 1



13 FM 200 flooding Fire Protection System – Computer Division. 1

14 Fire Detection & Alarm system – Mezzanine – 1 1

15 Fire Detection & Alarm system – Mezzanine – 2 1

16 Fire Detection & Alarm system – R & D Center. 1

17 Water sprinkler – LPG bullets. 1

18 Hydrant System – to cover the entire plant. 433 Hydrant

points

19 Fire Hoses – 15 Meters / 30 Meters. 613 Hoses

20 Hose Boxes 165

21 Fire Branches 456

22 Multi Purpose Fire Nozzles. 3

23 Foam Making Branches. 4

24 Fire Tenders – water / Foam / DCP / CO2. 3

SN Particulars Remarks

25 Trailor Fire Pump. 2

26 Foam Trailor. 5

27 Foam Pumping System. 1

28 Smoke Exhausters. 4

29 Breathing Apparatus sets. 7

30 Breathing Apparatus refilling compressor. 2

31 Gas tight suits (Viton) – Specially for LPG 2

32 Proximity Suit. 1

33 Dry Chemical Powder. 1.2 MT

34 ABC Powder. 3.5 MT

35 AFFF Foam – 6% 4.5 MT

36 Fire Hydrant Pumps (Diesel), Capacity- 76 Lit/ Sec 1

37 Fire Hydrant Pumps (Electrical), capacity- 76 Lit/Sec each 4

38 Fire Pump (Jockey) Capacity-24 Lit/ Sec 1

39 Fire Pump – Booster. 1

40 Water reserve for fire 2750 M3

* * *

Annexure-26

LIST OF HOSPITALS

SN NAME OF HOSPITAL ADDRESS PHONE NOS1 Sethi Hospital 301-302/4, Model Town,

Basai Road, Gurgaon. 23215392332124

2 Aryan Hospital Old railway Road, Gurgaon 2321845/ 2330945

3 Gupta Nursing HomeMaruti Road Gurgaon, New Railway Road, Gurgaon

2322423

4 Lall Nursing Home New Railway Road, Gurgaon 2322410

5Batra Maternity Clinic, & Nursing Home

Shivaji Nagar, Khandsa Road. Gurgaon

2321240

6 Pushpanjali Hospital Civil Lines, Gurgaon 2323052/23200507 Saraswati Hospital Delhi Road, Gurgaon 2320191/2326191

8 Kalyani Hospital Mehrauli Road Gurgaon.23031012303102/2303103

9Umkal Hospital & MP Heart Research Inst.

A-520, Sushant Lok-1 Gurgaon.2385656/2385075

10Uma Sanjeevani Health Centre

1, Dakshin Marg DLF Qutab Enclave-II,

2350960/2351257

11 Sharma Hospital 47/5, Jacob Pura Gurgaon 2320944SOUTH ZONE HOSPITALS IN DELHI

1 Holy Family HospitalNew Ashram Chowk New-Delhi

26845900 to 909

2All India Institute of Medical Sciences

Ansari Nagar, New-Delhi 2661123/2668045

3Mool Chand Kherati Ram Hospital

Lajpat Nagar, New-Delhi 26833404

4 Batra Hospital 1, Tuglakabad Inst. Area,N-Delhi 26443747

5 Bahal Skin Institute N-Block, Greater Kailash, New-Delhi26443492649670

6Jeevan Hospital & Nursing Home

Jeevan Nagar,New-Delhi 2630243

7 National Heart Inst49, Community Centre East of Kailash, New-Delhi

2681597

8 Sukhda Nursing HomeLocal Shopping Centre R-Block, Greater Kailash New-Delhi.

2641647526416440

9 Majeedia Hospital Hamdard Nagar, New-Delhi 2608407

10 Ashlok Nursing Home25-A, Community Centre safdarjung Enclave, New-Delhi

261659012616586226165861

SN NAME OF HOSPITAL ADDRESS PHONE NOS

11Gujar Mal Modi Hospital & Research Centre New-Delhi

Mandir Marg, Saket New-Delhi26854611

12VIMHANS (Vidyasagar Inst.of Mental Health And Neuro-Sciences)

Nehru Nagar New-Delhi 26310510 to 520

13 Holy Angel’s HospitalPlot-B, Community Centre, Vasant Lok, Vasant Vihar, New-Delhi

14 Venu Eye Hospital C-40, South Extn.,New-Delhi15 Ortho nova hospital Madan Gir, New-Delhi16 Vasant Lok Hospital Vasant Vihar, New-Delhi 26149422/2614942317 NPH, Urology Centre 1A Jangpura-A 24310579/432

18 Summit Clinic9, Palam Marg,Vasant Vihar New-Delhi

614-3432/2653/4621

WEST ZONE.1 Bhagat Hospital D-2/48,Janakpuri 25551898

2Chajju Ram Memorial Hospital

Om Vihar Najafgarh Road New-Delhi.

2562368

3Sunil Memorial Nursing Home

RZ-13/1/6,Main Road, Palam Colony,New-Delhi

4 Vohra Nursing Home A-6,Rajouri Garden New-Delhi2502002/2505150

5 Khera Hospital2/12E,West Patel Nagar New-Delhi.

2562018

6Janakidass Kapoor Memorial Hospital

Naraina Road Ranjit Nagar,khanpur New-Delhi

25680922575611

7 Hemraj Jain HospitalNH-1,Block,C-1, Janakpuri,New-Delhi

25551507

8 Jivodaya Hospital Ashok Vihar, New-Delhi

9 Dr. Khera HospitalPandav-Nagar,Shadipur, New-Delhi

2562018/2567361

10 Mata Channan Devi HospitalC-1,Janakpuri, New-Delhi

11Sunderlal Jain Charitable Hospital

Ashok Vihar,Phase-III,New-Delhi.

12 Sir Ganga Ram HospitalOld Rajinder Nagar, New-Delhi.

25721800

13 Jaipur Golden Hospital2-Institutional Area Rohini, New-Delhi

2727142327260935

14 Sehgal Nursing HomeA0-6, Panchvati New Subji Mandi, Delhi

15 Gautam Hospital 2, Kohat Enclave Pitampura,Delhi-3416 Maharaja Agarsain Hospital West Punjabi Bagh 25454737

17 Amar- Leela HospitalB-1/6, janak Puri Main Najafgarh Road New-Delhi.

255308382559134525537965

NORTH ZONE1 Gouri Nursing Home 32-D, Kamla Nagar, Delhi

2 Mann Hospital GT Road,Roop Nagar, Delhi3 Tirath Ram Hospital 2,Battery Lane,Rajpur Road Delhi 23972087/239724874 St. Stephen Hospital Near Tis Hazari, Delhi5 Aggarwal Nursing Home Aggarwal Nursing Home EAST ZONE

1 Dr. Gupta Nursing HomeChand Tara Building, GT Road, Shahdara, Delhi

2 Gupta Nursing Home25. Raj Block, Navin Shadara,Delhi

3 Walia Nursing Home Shakarpur, Delhi

4Red Cross Hospital Society

Maternity Welfare&ChildCare Hospital, Seemapuri,New-Delhi

5 Pushpanjali Medical CentreA-14, Pushpanjali Vikas Marg, Extn Delhi.

6Deepak Memorial & Research Centre

Vikas Marg Extn. New-Delhi 2203380

7Gopal Nursing Home & Eye Hospital

B-1, Jyoti Nagar, (West)Loni Road, Delhi-110032

8 Roopali Nursing Home Yamuna Vihar, C-477-A, Delhi9 Anand Hospital Preet Vihar, Delhi 2224126

10 Shanti Mukund Hospital2, Institutional Area Vikas Marg Extn Delhi-110092

2157575/21520221

CENTRAL ZONE

1Shyam Lal Nursing & Research Centre

19, Ansari Road, Darya Ganj New-Delhi

2Jeevan Hospital & Nursing Home.

67/1,Rohtak Road New-Delhi

3 Jeevan Nursing Home2-B, Pusa Road New-DelhiPusa Road,

4 City Clinic17-A/1, Asaf Ali Road, New-Delhi.

5RB Seth Jessa Ram Hospital

Pusa Road, New Delhi

6Dr.B.L.Kapoor Memorial Hospital

Pusa Road, New-Delhi

7SanjeevanMedical Research Centre

4869/24,Ansari Road, Darya Gang, New-Delhi

* * *

Annexure – 27

LIST OF VEHICLES AVAILABLE

I) Company Vehicles (VIGILANCE)

S.No. Regn. No. of Vehicle Model Capacity Contact No

1 HR55D 6136 GYPSY 8 2277, 2288

2 HR55B-9783 VERSA SDX 7 2277, 2288

3 HR55D 4694 VERSA DX-II 7 2277, 2288

4 HR26AC 5702 VERSA DX-II 7 2277, 2288

5 HR26AF 1837 OMNI LPG 8 2277, 2288

6 HR55D 8710 OMNI PETROL 8 2277, 2288

7 HR55D 4696 OMNI PETROL 8 2277, 2288

8 HR55E 4839 OMNI PETROL 8 2277, 2288

9 DL2SM 1216 M/Cycle 2 2277, 2288

10 DL7SAT 4013 M/Cycle 2 2277, 2288

11 DL2SM 1191 M/Cycle 2 2277, 2288

12 HR26AH 4431 M / CYCLE 2 2277, 2288

13 HR26AF 8709 M/Cycle 2 2277, 2288

14 HR26R-6542 M/Cycle 2 2277, 2288

15 HR26AE 3766 M/Cycle 2 2277, 2288

16 DL9SG-3820 Scooter 2 2277, 2288

17 DL9SG-5097 Scooter 2 2277, 2288

II) Contractor Vehicles (Hired)

SN Type Regn No of vehicle

Capacity( Passenger )

Agency Phone / Mobile No.

1. WagonR DLY19576 4 Travel IndiaMr Dheeraj

Atreja

98102642749212579688

Mr. B.Bhardwaj (MSIL Factory) -

9873969820-

Inter com- 3546

2. WagonR DLY19574 4 Travel India3. WagonR DLY19573 4 Travel India4. WagonR DLY19572 4 Travel India5. WagonR DLY19472 4 Travel India6. WagonR DLY19568 4 Travel India7. WagonR DLY19505 4 Travel India8. WagonR DLY19504 4 Travel India9. WagonR DLY19403 4 Travel India10. WagonR DLY19471 4 Travel India11. WagonR DLY19470 4 Travel India12. WagonR DLY19416 4 Travel India13. WagonR DLY19417 4 Travel India14. WagonR DLY19571 4 Travel India15. Esteem DLY1B0034 4 Travel India16. Esteem DLY1 B0099 4 Travel India17. Esteem DLY1 B0041 4 Travel India18. Esteem DLY1 B0133 4 Travel India

III) Department owned vehicle (Issued to Individual):-

Slno Dept Reg No

Allotted To Name Lvl

Cech Model Name Mobile No. Res No

1 HRSHR26AK-

8866 139548 MR. A D BURMAN DPM ESTEEM 9999255055 4253346

2 PG3HR26AL-

3212 191590 MR. VAIBHAV SHIAM DPM ESTEEM 9999653537

3 MKRHR26AL-

4695 193330 MR. VINAY PANT DPM ESTEEM 9811261533

4 ENPHR26AM-

5674 151890 MR. VINAMRA GUPTA DPM ESTEEM5 NCP HR26Y-7794 181269 Mr. MANOJ GAUTAM DPM ESTEEM6 LCE HR26Y-7848 109940 MR. R HARI KUMAR DPM ESTEEM 9811312090 261324217 PI2 HR26Z-0578 144711 MR. D THUKRAL DPM ESTEEM 4144001

8 VGLHR26AA-

2343 183113 MR. DEEPAK ANAND DPM ESTEEM 9910173500 4008158

9 SNWHR26AA-

3544 117323MR. PRAVEEN

GUPTA DPM ESTEEM 4080666

10 EN8HR26AA-

4505 148784 MR. ALOK JAITLEY DPM ESTEEM 9810793640

11 AG2HR26AA-

3239 126195 MR. V P SINGH DPM ESTEEM 9811144522

12 SATHR26AA-

4934 110752 MR. P CHAKRABARTT DPM ESTEEM 9811801399

13 CARHR26AD-

3178 184691 MR. RAJESH GUPTA DPM ESTEEM 3207714

14 SACHR26AD-

9605 185329 MR. SANJAY MATH DPM ESTEEM 9999666712 4116582

15 VPEHR26AF-4424 181595 MR. UMESH NIGAM DPM ESTEEM 4014628

16 ND2HR26AF-6336 107441 MR. K VERMA DPM ESTEEM

17 MSNHR26AF-6111 147931 MR. S M MURMU DPM ESTEEM

18 IM2HR26AF-7145 148555 MR. RAJIV KR AGAR DPM ESTEEM

19 MCEHR26AG-0892 151670 MR. RAVI SINGH DPM ESTEEM

20 PIMHR26AG-1873 148563 MR. SULTAN SINGH DPM ESTEEM

21 TAXHR26AG-1884 187577 MR. VIVEK KHETARP DPM ESTEEM 9810226392 26131565

22 PG2HR26AG-9601 188522 MR. SANJEEV HANDA DPM ESTEEM 9811609800 2381110

23 PS2HR26AH-2906 147087 MR. SANJAY SARVAH DPM ESTEEM 4144441

24 SR1HR26AJ-2269 189790 MR. C S V CHARI DPM ESTEEM 9999030817 22743509

25 EMRHR26W-6633 183660 MR. ANIL GAUR DPM ESTEEM 9811888038 4356953

26 PNEHR26W-2247 103691 MR. T K BANERJEE DPM ESTEEM 25073864

27 EA1HR26W-2026 128287 MR. A S NIRVAN DPM ESTEEM 2765288

28 PAPHR26W-4499 118737 MR. R S KAPOOR DPM ESTEEM 9811391080 2385200

29 ASEHR26W-2245 116882 MR. HEMANT KUMAR DPM ESTEEM 26895292

30 ESSHR26W-2442 119350

MR. SUMANT MATHUR DPM ESTEEM 9811313661

31 MPCHR26W-2720 130192 MR. VIKRAM VERMA DPM ESTEEM 4045889

32 CFPHR26W-3294 137782 MR. G K DUA DPM ESTEEM 9811698112 41574104

33 LOGHR26W-2384 105120

MR. DEEPAK SHARMA DPM ESTEEM 26140465

34 EA2HR26W-2531 114219 MR. DEEPAK JAIN DPM ESTEEM 2369974

35 PI6HR26W-2684 114162 MR. S G BIDNURMAT DPM ESTEEM

36 MX2HR26W-2689 102814 MR. L K GUPTA DPM ESTEEM 4261017

37 MC1HR26W-2694 126128

MR. GANESH KAMATH DPM ESTEEM 28080579

38 VIMHR26W-2679 115908 MR. P K AGGARWAL DPM ESTEEM 25087091

39 PI3HR26W-2691 125997 MR. SUJAY GUPTA DPM ESTEEM

9811801881

40 ECS HR26W- 106941 MR. S K GANDHI DPM ESTEEM 2353142

2695

41 AS2HR26W-3308 146226 MR. MUKESH KR GUP DPM ESTEEM 2384518

42 EN2HR26W-6699 148407 MR. TAPAN SAHOO DPM ESTEEM

981180339926123399

43 EDDHR26W-3295 108200 MR. RANJAN VASISH DPM ESTEEM

44 ITIHR26W-3395 107824 MR. RAJEEV KHURAN DPM ESTEEM 25074744

45 VI1HR26W-3415 142085 MR. PRAG BASIL DPM ESTEEM

46 VDDHR26W-3397 141968 MR. SUNIL KR KAKK DPM ESTEEM 32541245

47 PI4HR26W-6429 118389 MR. R K JAIN DPM ESTEEM 4269076

48 MT4HR26W-6863 104400 MR. S K GUPTA DPM ESTEEM 2581342

49 SNDHR26W-7066 126853 MR. P K VERMA DPM ESTEEM 9811802896

50 QA4HR26W-6862 132772 MR. PRITIMAN DEY DPM ESTEEM 2219256

51 EM3HR26W-6434 103942 MR. L N RAO DPM ESTEEM 9911557435 2380309

52 WS1HR26W-8624 149900 MR. VIKRAM SARIN DPM ESTEEM 4370822

53 VI3HR26W-7652 112852 MR. A K MANDAL DPM ESTEEM 9811818868

54 WADHR26W-7245 123978

MR. A BANDYOPADHY DPM ESTEEM 9899841072 4040519

55 ISLHR26W-6857 147540 MR. S N BARMAN DPM ESTEEM 9899810607

56 ASMHR26W-7691 104167 MR. R K MEHTA DPM ESTEEM 3297736

57 EN7HR26W-7647 126225

MR. DEEPAK SAWKAR DPM ESTEEM

98118181624061635

58 EM1 HR26X-0746 102180 MR. S R RANA DPM ESTEEM 2582290

59 PI1HR26W-7697 118710 MR. RAJIV GUPTA DPM ESTEEM 4364105

60 PSEHR26W-7927 114251 MR. SANJAY THAKAR DPM ESTEEM 2460284

61 ND1HR26W-7925 125598 MR. R K DUGGAL DPM ESTEEM 9811317997

62 PPCHR26W-9022 144541 MR. AMRITA MITRA DPM ESTEEM

63 CMPHR26W-9013 138460 MR. RAJIB MEHRA DPM ESTEEM 9811796786

64 MC3HR26W-9335 147036 MR. PV RAVIKUMAR DPM ESTEEM 4261016

65 AS2HR26W-9989 126047 MR. S K KHANWALKA DPM ESTEEM 25082234

66 CONHR26W-9996 102199 MR. A K AGGARWAL DPM ESTEEM 25120291

67 AS1 HR26X-1783 126071 MR. D SUBRAMANIA DPM ESTEEM 26166780

68 EA3 HR26X-3426 139718 MR. SANJAY KHARE DPM ESTEEM 4041655

69 JPSHR26AM-0318 107255 MS. MANJU GUPTA DPM SWIFT 9811411751

70 EN3HR26AM-1374 144657 MR. B R KUMAR DPM SWIFT

98113878804361121

71 EM2HR26AM-2691 152994 MR. SANJAY BARONI DPM SWIFT 3260970

72 WDEHR26AM-5671 148776 MR. SANDEEP RANJA DPM SWIFT

73 PS3HR26AM-3514 146242 MR. P V KRISHNA DPM SWIFT 4048985

74 HRMHR26AM-5670 812234 MR. MANOJ JAISWAL DPM SWIFT

75 ENBHR26AM-5312 156787 MR. SRIKANTH SUDH DPM SWIFT 9811081909 4377582

76 PG1HR26AM-5679 195170 MR. VIVEK B. DPM SWIFT 9999363630

77 WS3HR26AM-6384 151874 MR. SHOBHIT MITTA DPM SWIFT 2574993

78 MP1HR26AM-7342 102806 MR. V K ARORA DPM SWIFT 4048508

79 QA2HR26AM-8498 151700 MR. VIPIN GARG DPM SWIFT

80 WSMHR26AN-0421 146285

MR. CHEGU DHANUMJ DPM SWIFT 2580561

81 DD1HR26AN-7868 161764 MR. HARDEEP SINGH DPM SWIFT 9873425873 4273490

82 SR4HR26AC-2332 103667 MR. B S YECHURY DPM YN4 DX 9811911190 24672979

83 AG3HR26AC-4484 145114 MR. VIPIN JAIN DPM YN4 DX 9873170280 4048859

84 VI2HR26AD-4148 148539 MR. PARIKSHET MAI DPM YN4 DX 4086959

***

Annexure –28

(A) LIST OF CONTROLLED COPIES OF THE ON SITE EMERGENCY MANAGEMENT PLAN & DISASTER CONTROL MEASURES

Sl. No. Name of the Employee Designation Dept./Div

1 D D KALAChief Safety Officer

SNW

2 SANJAY KHARE DPM SNW3 C S RAJU DDVM PHR4 S Y SIDDIQUI MEO ADMIN

5 M M SINGHFACTORY MANAGER & MEO

PROD

6 RAJIV GANDHI DVM FCE

7 V VARSHNEY DVM PRDS

8 VIKRAM KHAZANCHI DDVM PMNT9 S R RANA DPM EM1

10 L N RAO DPM EM211 SANJAY BARONIA DPM EM312 A K SINGH MGR PS113 SANJAY SARVAHI DPM PS214 S K YAGYSENI DPM PS315 ECC-1 SNW16 ECC-2 SNW17 Fire Station SNW

(B) DISTRIBUTION COPIES:-

TEAM LEADERS / ALL FMGRS / DPM / SFMGR1 / DDVM / DVM / EO / MEO/ MEO& DIR.

* * *

_________________________________________________________________________


Annexure – 29

LIST OF PERSONAL PROTECTIVE EQUIPMENTS(Minimum stock maintained in Fire Station Stores)

SN Equipment Quantity

1. SCBA 52. Breathing Apparatus refilling compressor 23. Gas tight Suit (Viton) specially for LPG 24. Face mask with chemical cartridge 105. Proximity Suit 26. Full body safety harness (Safety Belts) 107. Megaphones 28. Head lamps- Torches 59. Safety goggles 1010. Safety Shoes 1011. Safety Helmets 10

* * *

Annexure - 30

CYCLONE/FLOOD EMERGENCY PROCEDURES

1. Pre-cyclone season checks – To be carried out at the beginning of the cyclone season.

Electricity Supply

Check that all trees adjacent and under the overhead power lines are trimmed and will not foul the lines.

Storm Water Drains

Ensure that all storm water drains and guttering is free of obstruction

2. Procedure as Cyclone Approaches

These procedures are divided into two sections:

Green Alert

When the Weather Bureau advises that a cyclone or potential cyclone is located within 600 kilometres, but there is NO strong indication of gales affecting within 24 hours, it is referred to as `Green Alert’.

Red Alert

When the Weather Bureau advises that a cyclone is within 600 kilometres and gales are expected within 24 hours, then it is referred to as ‘Red Alert’.

A Cyclone Control team will function under the ECC.

Green Alert Procedures

Check that the electric pumps are in working order. Check that all rubbish bins and other items of plant that could become flying

debris are placed in secure locations, preferably indoors. Check that all building materials are properly secured. Departmental projects, experiments etc., which could be affected by failure of

electricity, gas or water should be safeguarded. It is the responsibility of the Heads of Departments to establish their own procedures to cater for this type of emergency.

Red Alert Procedures

Departmental projects, experiments etc. shall be safeguarded as per departmental requirements.

All doors and windows to be secured. If the building is occupied during the cyclone, windows shall be operated in accordance with standard cyclone procedure, i.e. those on one side away from wind should be opened.

All heavy sliding and roller doors shall be shut and locked in the shut position. Electric driven stand-by pump shall be checked. A final check shall be made of storm water drains to ensure inlets are not

blocked. A final check shall be made around buildings to ensure that all loose items have

been secured. All plantings etc. shall be moved from display benches in the bush house and

stored beneath the benches. Keys to all pool vehicles except those used by watchmen shall be available at the

Main Building.

After Cyclone has passed

Immediately after the cyclone has passed all buildings shall be checked for damage and details should be forwarded to the Control team.

Security arrangements shall be provided for any damaged or open buildings. Cleaning and mopping up of damaged buildings should be carried out as soon as

possible. Loose equipment secured during Green and Red Alert shall be returned to

normal locations.

* * *

Annexure - 31EARTHQUAKE EMERGENCY PROCEDURE

During a major earthquake shaking of the earth or building is experienced. This shaking may start out as a gentle rocking motion that grows violent, or it may begin as a violent jolt. You will find it difficult to walk during the shaking.

During the quake1. Stay where you are, get under a desk or table or stand in a doorway or the

corner of the room. Do not seek cover under tables or benches in laboratories. Chemicals could spill and harm you. If possible, extinguish fires, flames or other sources of ignition.

2. If you are outside get into an open area away from buildings, power lines and trees.

3. Do not use elevators. 4. If you are driving, pull over to the side of the road and stop immediately. Avoid

overpasses and power lines. Stay inside the vehicle until the shaking has stopped.

After the quake

1. Gather your valuables and leave the building quickly. If necessary, provide assistance to those who have been trapped in the building, including those with mobility impairments or those who are trapped by debris. Gather at the designated meeting location.

2. To expedite rescue and emergency services, a sign should be posted on the front of the building denoting that all of the occupants got out or that people may be trapped in the building. If you know someone is trapped, note the time, date, number of victims and their last known locations on the sign.

3. Check for injuries, but do not move seriously injured people unless the danger in the area is greater than their injuries.

4. Remember, a significant earthquake will affect the entire city and country. You may have to fend for yourself and your fellow workers for quite a long time. Render whatever aid you can provide, but remember that you are responsible for your personal safety.

5. Use telephones only to report emergencies (i.e., gas leaks, fire, injuries).

6. Physical Plant or other trained individuals should turn off utilities.

7. Never touch downed utility poles or lines. Avoid damaged building equipment.

8. Do not use your vehicle unless there is an emergency. Keep the streets clear for emergency vehicles.

Be prepared for aftershocks. Aftershocks are usually smaller than the main quake, but they may be strong enough to topple already damaged buildings.

* * *

Annexure- 32

SPECIAL EQUIPMENT AVAILABLE NEARBY

SR OWNER / COMPANY NAME

ADDRESS CONTACT TEL NO

EQUIPMENT AVAILABLE

1 M/s Rajendra Earthmovers Mr Rajendra Yadav

Near Bristol Hotel, Gurgaon

2353159 off2385728 ResiM- 9810100291

02 Nos JCB

2 M/s Ram Earthmovers Mr Satish Yadav

Vill & PO.Kanhai , Gurgaon

M- 9819373225M- 9810981275

03 Nos JCB

3 M/s Kasania & Company Mr Rajpal

DLF Phase-III,Nathupur, urgaon

M-9810101979 03 Nos JCB 02 Nos Spokeland

4 Rampal & Company

Mr Rajpal

Vill & PO Mullahera, (Near Huges Software Systems ) Gurgaon

M-9811197774 Mobile crane & fork lifts

5 Indian Infrastructure Equipment LimitedMr Kautav Saikia, Reg. MgrMr Arun Bhatia, PA to I/C

Old Delhi Jaipur Road, Opposite PASCO Auto, Gurgaon

M- 9818075172, O- 0124-309201

JCB Backhoa loader,Excavator, Fork Lifts, Transit Mixer

* * *

Annexure 33

List and telephone directory of NGO

SNO NAME OF THE NGO ADDRESS PHONE NO.

1. Indian Red Cross Society, Distt. Branch , Gurgaon

Jail Road ,Gurgaon 2320468

2. District Council for Child Welfare Bal Udyan,Civil Lines, Gurgaon 2328288

3. Haryana Welfare Society for Hearing and Speech Handicapped,Gurgaon Branch

Mehrauli Road, Near I.T.I. Gurgaon

2320698

4. Rotary Club,Gurgaon 98-L,New Colony, Gurgaon 2327015 2327212

5. Rotary Club,DLF Qutab Enclave G-11/8 D.L.F. Qutab Enclave,Phase-I, Gurgaon

2350529

6. Lions Club, Gurgaon city 99, Sector-15, Part-I, Gurgaon 2321695

7. Lioness Club, Sukarma DLF Qutab Enclave

K-19/4, Phase-II, Qutab Enclve City, Gurgaon

2350262 2351235

8. Lions Club, Sohna Town Bharat T.V. Centre Near Bus Stand, Sohna

2362169

9. Lions Club, Taoru Town Vijay Chowk, Taoru 72242

10. All India Confederation of Blind, Gurgaon Branch

Village Behrampur, Distt. Gurgaon

11. National Association for Blind 168-B, New Colony, Gurgaon 2321156

12. All India Crime Prevention Society 606, Street No.-8, Madan Puri, Gurgaon

2330245

14. India Medical Association, Gurgaon Kashiram Medical Services 344/4, Jacobpura, Gurgaon

2325011 2323377

15. Khushboo Welfare Society, Gurgaon 4B,Friends Colony,Jharsa Road,Gurgaon

2321243

17. Sadbhawna Charitable Trust S.C.O. No-11, Sector-4, Gurgaon 2322938 2341060

18. Vinayak Charitable Trust 35, Purvi Marg D.L.F. City, Phase-II Gurgaon

2352741 2352600

SNO NAME OF THE NGO ADDRESS PHONE NO.

19. Joint Assistance Centre G-17/3, D.L.F. Qutab Enclave, Phase-I, Gurgaon

2352741 2353833

32. Resident Welfare Association, Sector 14-17, Gurgaon

2322836 2322124

33. Resident Welfare Association, Sector 4-7, Gurgaon

2051, Sector-4, Gurgaon 2320522

34. Gurgaon Chamber of Commerce and Industries

P.O. No.-2, Khandsa Road, Gurgaon

2370303 2370404

35. Gurgaon Distributors Association Chandna Sales Agency, Main Jacobpura Road, Opp. Kulwant Studio

2324851 2322320 2324851

36. Gurgaon Udyog Association 785, Phase-IV, Udyog Vihar, Gurgaon

2340634

37. Gurgaon Industrial Association G.I.A. House, Industrial Development Colony, Mehrauli Road, Gurgaon

2320746

* * *

Annexure 34

Telephone directory of mutual aid group/ others

Name Organization

Name and designation of

contact person

Telephone Nos.

Civil Fire Brigade, Sec-29,Gurgaon Fire Station

0124-2392101,2392102,2392103,(SO-9350690297)(FO-2392201, 9350690293)

Civil Fire Brigade, Bhim Ngr,New Rly Raod,Gurgaon Fire Station

0124-101, 2320101, 2328868 (CFO-9350690288, 9810268320)

Air Force Fire Brigade, 54, ASP, Gurgaon Fire Station 0124-2345646-470124-2340441/447

AFSCTS, Sohna Road, Gurgaon Fire Station 0124-2200052-54,0124-22000202

503, SU, AF Station, Arjangarh, New Delhi Fire Station 011-26502031/222

3 WING AIR FORCE , PALAM, DELHI Fire Station 011-25697561

25 ASP, Rajokari, New Delhi Fire Station

011-25063504/06 Extn 222 & 217,011-25063536/444

Delhi Fire Service Control Room, Cannought Place, New Delhi

Fire Station

011-101011-23314444011-23412222011-23412223011-23412235

* * *

Annexure 35

EMERGENCY EVACUATION PROCEDURE FOR GENERAL EMPLOYEES

Understand the emergency situation from Emergency Response Team (ERT) member and follow his instructions.

1. Do not panic.

2. Do not waste your time in switching off computers / collecting your

belongings.

3. Do not run, walk brisk.

4. Do not try to over take / push others while

Getting out

5. Always walk on the left side of the staircase.

6. Assemble at the designated assembly points.

7. Come out through the emergency Exit which is nearest to your work place OR

prescribed in the chart

Notes:

In case of fire / smoke, crawl to escape. Use a wet handkerchief to cover your

nose.

In case of earthquake, move out of the complex, to the nearest open area.

In case of earthquake, do not stand near glass windows and walls.

* * *


Annexure 36

TELEPHONE DIRECTORY OF NEARBY CONTACT PERSON IN COMMUNITY ( VILLAGES )

Detail of Community / street / mohalla/ Village

Name and designation of contact person

Address of contact person

Telephone Nos.

Sirhaul Village Naresh Yadav Sarpanch 9810854721

Karterpuri Village Balbir Singh Sarpanch 9212922230, 9891352208

Annexure 37

TELEPHONE DIRECTORY OF NEARBY CONTACT PERSON IN INDUSTRIES

Name Industry Name designation Address of contact person

Telephone Nos.

M/s Bharat Sheets Limited

Dr. D.P. Sahu VP (HR) Plot no 1, MUL JV, Complex GGN

4154 / 4193 2341087, 9871014413

M/s SKH Metal M S Johar HOD-HR Plot no 2, MUL- JV, Complex GGN

316, 4017613 to 618,9999684311

M/s Machino Plastics Limited,

Ajay Khanna HOD-HR Plot no 3, MUL JV, Complex GGN

4186, 2340806, 2347601 ,9871064488

M/s JBML Piju V HOD-HR Plot no 5, MUL JV, Complex GGN

4185, 2398446248,9810168895

M/s CAPARO Maruti Limited

Ratan Yadav GM(HR) Plot no 7, MUL JV, Complex GGN

4183, 4318160,981800947

PANSUT UDYOG Udyog Vihar, Gurgaon

LUMAX PVT. LTD K N Gupta GM (PLANT) Plot no- 16, Udyog Vihar, Gurgaon

2341090, 2341324,9810088413

ORIENT CRAFT LTD Plot no-14, Udyog Vihar, Gurgaon

JAIN CAMAR Plot no-12, Udyog Vihar, Gurgaon

MUNJA SHOWA R K Arora Pers Mgr (HR & ADMIN)

Udyog Vihar, Gurgaon

27, 2341001,2340427 9810422349

FIAT SERVICES, Orix & Auto Business Solution

Plot no-7B, Udyog Vihar, Gurgaon

3014700

OTIE INDIA P LTD Plot no- 7A, Udyog Vihar, Gurgaon

ORIENT CRAFT LTD Plot no- 7D, Udyog Vihar, Gurgaon

AGILENT TECHNOLOGY

Plot no-7C, Udyog Vihar, Gurgaon

SIMENS, Plot no- 6A, Udyog Vihar, Gurgaon

ANAND GASESE Plot no-6, Udyog Vihar, Gurgaon

MATLEX, Plot no-4, Udyog Vihar, Gurgaon

SVAM POWER Plot no-3, Udyog Vihar, Gurgaon

ANSOL UDYOG Mr ANIL SHARMA

PEARL POLYMERS, Plot no-2A, Udyog Vihar, Gurgaon

234589

HSEB OFFICE TUPPER WARE, Plot no- 1A,

Udyog Vihar, Gurgaon

***

ANNEXURE - 38

RECORD OF AMENDMENTS

Date of change

The page number and description of each change made Signature of the person making the change

27TH 30TH

Sept. 2007Plan Risk evaluation had been included and Risk assessment of LPG Bullets area, GAIL terminal, HSD storage area, CNG filling station, auto LPG filling station was carried out & included in the plan. On the basis of plan risk evaluation, entire plan was reviewed.

D D KALA

31ST Mar 2008

Entire plan was revised on the basis of change in the organization structure & name of the organization. Page number has been given chapter wise. D D KALA

31ST July 2008

Occupier of the company changed. The plan was revised on the basis of the organization changes. The same has been updated in the respective pages. D D KALA

_________________________________________________________________________


Annexure 39

FORMAT FOR COMMUNICATING THE CHANGES IN ON SITE EMERGENCY MANAGEMENT PLAN AND DISASTER CONTROL MEASURES

Information Change number:

Date of circulation:

Date of review and changes:

Reason of change:

Effective date:

Type of changes:

Details of changes: Chapter: Paragraph / Annexure / point number:

Page number:

Existing information / procedure:

Changed / modified information / procedure:

Updated by: Checked by Approved by

Annexure-40

DETAILS OF PERSONS INVOLVED IN PREPARATION OF ON SITE EMERGENCY

MANAGEMENT PLAN AND DISASTER CONTROL MEASURES ( REVISED )

Name Designation Address Experience

1. Sh A Y

SUNDKAR

Asstt Director National Safety Council,

Mumbai

10 Years

2 . Sh Dinesh Vaidya Expert Panel Member National Safety Council,

Mumbai

15 Years

3. Sh B R Sharma Safety Consultant Microtek Engineers &

Consultants, Gurgaon

25 Years

4. Sh D D KALA Chief Safety Officer Maruti Suzuki india Limited,

Gurgaon

25 Years

Annexure - 41

ABBREVIATIONS USED

APELL : Awareness and Preparedness for Emergencies at Local Level

AP : Assembly Point

ECC : Emergency Control Centre

FE : Functional Exercise

FSE : Full-Scale Exercise

IC : Incident Controller

IDLH : Immediately Dangerous to Life or Health

MCP : Manual Call Point

MSDS : Material Safety Data Sheet

MSIHC : Manufacture, Storage and Import of Hazardous Chemicals

OEP : On-Site Emergency Plan

PA System : Public Address System.

PPE : Personal Protective Equipment

SC : Site Controller

SCBA : Self-Contained Breathing Apparatus

SOP’s : Standard Operating Procedures

STEL : Short-Term Exposure Limit

TLV : Threshold Limit Value

TTE : Table-Top Exercise

Annexure - 42

GLOSSARY

GLOSSARY OF TERMS

Accident2: Unplanned event giving rise to death, ill health, injury, damage or other losses to personnel or property (IS-18001)

Emergency1: It is one which has the potential to cause serious injury or loss life and/or property and which tends to cause disruption inside and /or outside the works.

Emergency Control Centre4: It is a place from which the operations to handle the emergency are directed and coordinated.

Emergency Plan7 : A formal written plan which, on the basis of identified potential accidents together with their consequences, describes how such accidents and their consequences should be handled, either on-site or off-site.

Emergency Response: The efforts to minimize the severity of an accident by protecting the people, the environment or the property and bring back the scene to normal pre-emergency conditions.

Evacuation: Removal of persons from the accident site / neighbouring place and diverting them to assembly point.

Hazard2: A source or a situation with a potential to cause harm in terms of human injury or ill health, damage to property, damage to the environment or a combination of these.

Hazardous Chemical: Hazardous chemicals means any chemical which satisfies any of the criteria laid down in part I of Schedule I or listed in column 2 of part 2, any chemical listed in Column 2 of Schedules 2 and 3 of the Manufacture, Storage and Import of Hazardous Chemicals Rules, 1989.

Hazards: Analysis: Identification of undesired events that may lead to the materialization of the hazard. The analysis of the mechanism by which those undesired events could occur and usually the estimation of the nature, characteristics and magnitude of the possible loss/damage to life and property. The loss/damage, severity would be analyzed and assessed for each hazard identified.

IDLH Value6: Immediately Dangerous to Life or Health (IDLH) is a condition “that possesses a threat of exposure to airborne contaminants when that exposure is likely to cause death or

immediate are delayed permanent adverse health effects or prevent escape from such an environment”.

On-Site Emergency: An accident, which takes place within the boundaries and its effects are felt within the premises involving the people working within the specified boundaries.

Off-site Emergency: An accident, which takes place within the boundaries but its effects are also felt outside the premises involving the general public in the vicinity.

Incident Controller4: The person who will take control of handling the emergency at the incident site.

Site Controller (SC)): The person who has the overall responsibility of directing operations from the Emergency Control Centre.

Vulnerable Zone5: It is an area, which may be affected or exposed by the release of hazardous chemicals.

Sources:

1. Loss Prevention in the Process Industries – Hazard Identification, Assessment and Control (Second Edition) by Frank P Lees

2. IS-18001: 2000 – Occupational Health and Safety Management Systems – Specification with Guidance for Use

3. Major Hazard Control – A Practical Manual, an ILO Publication 4. Technical Guidance for Hazard Analysis by US EPA5. National Institute of Occupational Safety and Health, US Department of Health and

Human Services – Pocket Guide to Chemical Hazards (June 1994 Edition)6. Guiding Principles: Chemical Accident Prevention Manual, OECD, 2003

* * *