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Address Of Your Company
ON SITE EMERGENCY PLANON SITE EMERGENCY PLAN
Month & YearMonth & Year
REVISION -IREVISION -I
Prepared By Checked By Approved By
Safety Officer Safety Manager Unit Head
[Names & Signature]
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INDEX
CHAPTERNO.
TOPIC PAGE NO.
1 PREFACE 4
2 PREAMBLE 5 - 9
1 Emergency 52 Nature of Emergency 53 Process Description 64
Identification of Hazardous Area 65 Objectives of the Plan 76
Emergency Control Center 77 Assembly Points 88 Codification of
Sirens 89
1011
Training & EducationMock drillUpdating the Plan
999
3 EMERGENCY ORGANISATION 10
4 KEY PERSONNEL AND THEIRRESPONSIBILITIES
11 - 15
1 Site Controller 112 Incident Controller 12
3 Personnel / Administrative Manger 134 Security Officer 135
Departmental Heads 146 First Aid team 147 Factory Fire Squad
Personnel 15
5
6.
EMERGENCY ACTION PLAN
LIST OF ANNEXURES
16-22
23-49
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9 Training & Education 10
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------------------------------
LIST OF ANNEXURES
A. Brief description of the manufacturing process
B. Telephone numbers of Police, Fire Brigade, Hospitals &
other outsideEmergency Services
C. Telephone numbers & addresses of Key Personnel
D. Telephone numbers of MARG members.
E. List of Fire and Rescue Squad Members
F. Information on Fire hydrant System
G. List of fire Extinguisher.
H. List of Personnel Protective Equipment.
I First aid medical facilities.
J List of Some hazardous Chemical and action.
K Scenario Based Emergency action.
L Emergency organization Chart
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------------------------------
CHAPTER 1
PREFACE
1.1 The enclosed On-site Emergency Plan is made forthe Bulk drug
manufacturingplant of M/s XYZ Ltd. Plot No: XYZ, MIDC,
___________
1.2 The plant has a manufacturing facility to produce Bulk Drug
viz..
1.3 The plant is designed and equipped to handle hazardous
chemical and to carry
out various processes and operations on these chemicals. The
plant is provided
with Fire Hydrant system, Fire extinguishers and Scrubber
system. In addition to
this adequate types and number of Personal Protective
Equipement, First Aid
Boxes, Eye washers, Ventilation system has been provided.
1.4 Considering the types of operations carried out in the plant
and the nature, extent
of hazards existing, the management of M/s XYZ LTD thought it
necessary to
have some system of tackling an emergency.
1.5 The formulation of this document is an outcome of the above
thought process.
------------------------------
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CHAPTER 2
PREAMBLE
In spite of various preventive and precautionary measures taken
in the plant, the
possibility of a mishap cannot be totally ruled out. Hence, the
need to prepare a
Contingency Plan for dealing with incidences which may still
occur and are likely to
affect LIFE and /orPROPERTY, both within the plant and in the
immediate
neighborhood.
Such an emergency could be the result of malfunction of the
Plant & Equipment or non-
observance of operating instructions. It could, at times, be the
consequence of acts
outside the control of plant management like severe storm,
earthquake, flooding, or
deliberate acts of arson or sabotage.
A Major Emergency in the plant is one that may cause serious
injury or loss of life and
damage to the property.
This On Site Emergency Plan (OEP) explains the code of conduct
of all personnel in the
plant along with the actions to be carried out in case of an
Emergency. This plan gives
the guidelines for employees, contractors, transporters, etc. It
not only defines
responsibilities but also informs about prompt rescue
operations, evacuations,
rehabilitation, co-ordination and communication.
1. EMERGENCY:
An Emergency is a situation, which may lead to or cause
large-scale damage ordestruction of life, property or environment
within or out side the Factory. Such
an unexpected situation may be too difficult to handle for the
normal work force
within the plant.
2. NATURE OF EMERGENCY:
The emergency specified in the OEPrefers to occurrence of one or
more of the
following events: -
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a. Fire/Explosion.
b. Major accident such as structural or building collapse,
overturning of road
tanker containing flammable substances.
c. Natural calamities like storm, flood, earthquake, etc.,
d. Sabotage act of terrorism, civil commotion, air raid etc.
3. PROCESS DESCRIPTION:
A brief description of the Manufacturing Process is given in
Annexure A.
4. IDENTIFICATION OF HAZARDOUS AREAS:
HAZARD AREA PROBABLE CAUSE OF THE
ACCIDENT
Explosion Boilers / Transformers/ Receivers for the
Aircompressors.
Malfunctioning of theSafety Valve
Flammable PetroleumProduct Storage Tank/ Drum Storagearea
External fire causingpressure built up in thetanks / barrels
Fire H.S.D. / FO StorageArea
Flammable vapor / airmixture and source ofignition.
Flammable PetroleumProduct StorageTank / Drum Storage
Shed /Production Area
Formation on pool in thedyke wall and source ofignition.
External fire Built up of
internal pressure Failure
of the top cover Tank onFire
Spillage Acid / Alkali StorageArea
Spillage of Acid / Alkali dueto rupture of the pipe
line,collapse of the storage tank
.
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5. OBJECTIVES OF THE PLAN:
a) To control the emergency, localise it and if possible
eliminate it.
b ) To avoid confusion, panic and to handle the emergency with
clear cut
actions.c ) To minimize loss of life and property to the plant
as well as to the
neighbourhood.
d ) To make head count and carry out rescue operations.
e ) To treat the injured persons.
f ) To preserve records and to take steps to prevent
recurrence.
g ) To restore normalcy.
6. EMERGENCY CONTROL CENTRE:
For the purpose of handling emergency, the following Emergency
Control
Centres has been identified.
During normal working hours - The Administrative Office
During other times - The Security Office.
All communications to and from will originate at this CONTROL
CENTRE. The
Emergency Control Center will have the following: -
a) A copy of ON-SITE EMERGENCY PLAN.
b) List of important telephone numbers such as Police, Fire
Brigade, Hospitals, and other outside Emergency Services,
etc.
(Refer Annexure B).
c) List of key Personnel with addresses and telephone
numbers.
(Refer Annexure C).
d ) List of Fire and Rescue Squad Members (Refer Annexure
E).
e) Plant layout indicating storage of hazardous materials
f) List Fire Extinguisher. (Refer Annexure G).
g) Fire Fighting System (layout of Fire Hydrants)
h) List of Personal Protective Equipment (Refer Annexure H)
i) First Aid box.
7. ASSEMBLY POINTS
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In case of an EMERGENCY the employees should assemble near the
defined
Assembly Points, as indicated below: -
Fire Fighters - Area near Security Gate.
First Aiders - Area near Security Gate.
Others - Area near Security Gate.
Wind direction to be determined by the WIND SOCKS installed on
top of the
Engineering Building.THE EMPLOYEES SHOULD RUN PERPENDICULAR
TO
THE WIND DIRECTION AND NOT AGAINST / ALONG THE WIND
DIRECTION.
8. CODIFICATION OF SIRENS
Sr. SIRENS INDICATES AUTHORITY
1. 30 SECOND
CONTINUOUS
ON SITE
EMERGENCY (ALERT)
INCIDENT
CONTROLLER
2. 1 MINUTE
CONTINOUS
EMERGENCY
CONTROLLED
(ALL CLEAR)
SITE CONTROLLER
NOTE: 1) EMERGENCY SIREN TO BE SOUNDED ONLY IF REQUIRED2) ALL
EMPLOYEES IN AREAS OTHER THAN AFFECTED TO CONTINUE
WORK UNLESS DISASTER SIREN IS BLOWN.
3) NO EMERGENCY ORGANIZATION MEMBER WILL LEAVE THE
EMERGENCY SPOT UNLESS `ALL CLEAR SIREN BLOWN.
------------------------------
9. TRAINING AND EDUCATION:
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Experience with on site emergency planning has proved the need
of training and
rehearsal. Major emergency procedure should be laid down clearly
and convincingly to
everyone on site particularly Key Personnel and Essential
workers.
It is obvious that in house or outdoor training is essential.
The duties and responsibilities
of each person and the emergency procedure to be followed by him
should be very
clear.
a. Seminar/refresher guidance On Site Emergency Plan.
b. Emergency instruction Booklet.
Seminar: Seminar is conducted in house/. Site controller will
explain the plan to all
associated concerned employees.
Expert from outside explain the plan to all associated concerned
employees. Expert
from also may be invited to impart training.
Emergency instruction Booklet:
Emergency instruction Booklet contains all detailed emergency
duties. The booklet
contains
Emergency duties,
Reporting relationship.
Thus everyone is conspicuous about his role in the Emergency
Plan.
10. MOCK REHEARSAL:
Inform all the employees about mock drill.
Fix the date for mock drill.
Observers will not be involved in the exercise. They will
monitor the Mock drill.
Emergency Siren / alarm will be raised.
After hearing the Siren / alarm, Emergency procedure will be
followed as
mentioned in the OEP.
Observer will note down the activities with respect to the
time.
11. UPDATING THE PLAN:
As and when required the On Site Emergency Management plan will
be updated. After
each drill the plan will be thoroughly received to take account
of shortcoming and
accordingly plan will be updated.
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CHAPTER - 3
EMERGENCY ORGANISATION
Responsibility will be automatically delegated in absence of
concern person/s in
following manner.
SITE CONTROLLER:
xyz
INCIDENT CONTROLLER:
DUTY OFFICER ON SUNDAYS/HOLIDAYS
ADVISORY COMMITTEE:
ALL HODs, Sachin K. Thorat
COMMUNICATION COMMITTEE:
P&A DEPARTMENTS
------------------------------
CHAPTER - 4
KEY PERSONNEL & THEIR RESPONSIBILITIES
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Key Personnels Responsibility during normal working hours :-
1. Site Controller:
He will retain overall responsibility for the factory and its
personnel. As soon as
he is informed of the emergency he shall proceed to the control
room and meet
the P&A. Manager. His duties shall be:
i) Assess the magnitude of the situation and decide if staff
needs to be
evacuated from their assembly points.
ii) Exercise direct operational control over areas other than
those affected.
iii) Maintain a continuous review of possible development and
assess in
consultation with Incident Controller and other Key personnel as
to whether
shutting down of the plant or any section of the plant and
evacuation of
persons is required.
iv) Liaison with Senior Officials of Police, Fire Brigade,
Directorate of Industrial
Safety, provide advice on possible effects on areas outside the
factory
premises.
v) Control rehabilitation of affected areas on discontinuation
of emergency.
vi) Issue authorised statements to news media, and ensure that
evidence is
preserved for inquiries to be conducted by statutory
authorities.
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2. Incident Controller:
On hearing of an emergency siren he will rush to the scene of
the occurrenceand take overall charge and report to Site
Controller. On arrival he will assess
the scale of emergency and decide if major emergency exists or
is likely and
inform the Communication Officer accordingly.
(1) Direct all operations within the affected areas with the
priorities for safety of
personnel minimise damage to the plant, property and minimise
loss of
materials.
(2) Pending arrival of Site Controller, assume the duties of his
post and, in
particular.
(3) (a) Direct the shutting down and evacuation of plant and
areas likely to be
adversely affected by the emergency.
(b) Ensure that all Key personnel and outside help are called
in.
(4) Provide advice and information to the Fire squad &
Security Officer and the
local fire service as and when they arrive.
(5) Ensure that all non-essential workers/staff of the areas
affected are
evacuated to the appropriate assembly points, and the areas are
searched
for casualties.
(6) In the event of failure of electric supply and internal
telephones, set up
communication point and establish contact with Emergency Control
Centre.
(7) Report on all significant developments to the P. & A
manager.
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(8) Have regard to the need for preservation of evidence so as
to facilitate any
inquiry into the causes and circumstances, which caused or
escalated the
emergency.
3. Human Resources Manager:
He will also work as liaison Officer and will be stationed at
the Main Entrance
(Security Office near Main Gate) during the emergency. He will
under the
direction of the site Controller handle police, press and other
inquiries, receive
reports from roll-call leaders from assembly points and pass on
the absentee
information to the Incident Controller. His responsibilities
shall include -
(1) To ensure that casualties receive adequate attention, to
arrange additional
help if required and information relatives.
(2) To control traffic movements into the factory and ensuring
that alternative
transport is available when need arises.
(3) When emergency is prolonged, arrange for the relief of
personnel and
organise refreshments / catering facility.
(4) From information received, advise the Site Controller of the
situation,
recommending (if necessary) evacuation of staff from assembly
points.
(5) Recruit suitable staff to act as runners between the
Incident Controller and
himself if the telephone and other system of communication fails
due to
whatsoever reasons.
(6) Maintain prior agreed inventory in the control centre.
(7) In case of prolonged emergency involving risk to outside
areas by wind-
blown materials, contact local Meteorological Office to receive
early
notification of changes in weather conditions.
4. Security Officer:
On hearing alarm advise fire squad and security staff in the
factory of the incident
zone and cancel the alarm. He will also announce through
telephone or
messengers to the HR Manager, Incident Controller and Site
Controller that
incident has occurred in such and such zone. He will open the
gates nearest to
the incident and stand by to direct the emergency service.
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If told of a large escape of gas he shall inform the Incident
Controller by
telephone and stand-by the telephone to receive further
messages.
On hearing the emergency alarm, he will immediately contact Site
Controller and
on his advice call the local fire brigade. In case fire is
discovered but no alarm is
sounding he shall receive information about location from the
person discovering
the fire and thereafter immediately consult the Site Incident
Controller and make
announcement on telephone telling the staff location of the
incident and to
evacuate to their assembly points. He will continue to operate
the switchboard
advising the calls connected with the incident to the
Communications Officer.
5. Departmental Heads:
The Departmental head wherein the incident has taken place will
report to
Incident Controller and provide assistance as required. They
will decide which
members of their staff they require at the scene.
6. First-aid Teams:
The Personnel Manager shall keep in security the roll call lists
for the fire
and first-aid teams on duty. Each Departmental Head for his
shift-team
appoints roll call leaders and first aiders. Roll call leaders
shall check their
rolls as members of the services report for emergency duty.
Names of any
unaccounted for absentees will be informed to the Security
Officer.
Members of first-aid Teams will report to the Incident
Controller on hearing
of the alarm in day time. The Emergency vehicle driver, if safe
to do so,
shall collect the emergency vehicle and park nearest to the
scene of the
incident. First aider shall inform the incident controller that
the Emergency
Vehicle is leaving the site, giving the name of the patient and
destination
i.e. hospital or doctors room and request the Incident
Controller to inform
the destination (hospital, etc.) advising them about the
casualties reaching
there.
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7. Factory Fire Squad Personnel:
The duty Fire fighting Squad under the command of the Security
Officer
shall be responsible for fire fighting and rescue. On hearing
the alarm, they
shall proceed to the place of incident. The men at security gate
shall find
out the location of the emergency and proceed to the site of the
occurrence.
At the incident scene, a team members detailed for this purpose
will check
squad members against roll-call sheet. At the site, all the
squad members
will respond to the advice and information given by the Incident
Controller
On arrival of the local fire brigade, they will also assist in
fire-fighting work
with the advice of the Incident Controller.
------------------------------
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CHAPTER - 5
EMERGENCY ACTION PLAN
ANY ONE NOTICING EMERGENCY SITUATION LIKE FIRE, EXPLOSION,
TOXIC
GAS LEAKAGE ETC. MUST
DOs
Attract the nearby person/employee by shouting FIRE FIRE
FIRE.
Seek help from the persons working nearby.
Try to control the incident at its initial stage with available
means/sources quickly.
Inform Shift In-charge / Duty Officer (In Night Shift ) about
the Incident.
DONTs
Do not be panicky.
Do not run Walk fast.
INCIDENT CONTROLLER MUST
DOs
A. IF FIRE / OTHER INCIDENTS ARE CONTROLLABLE
Approach the emergency site immediately taking note of wind
direction.
Assess the situation.
Inform Security Officer, Tell NAME, TYPE OF INCIDENT, ACTION
TAKEN,
HELP NEEDED and Order Security Officer/Guard to inform all KEY
persons.
Take lead in controlling emergency until such time concerned
Section Manager
takes over the charge.
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DONTS
Do not be panicky. Do not lose temperament.
B. IF FIRE/OTHR INCIDENTS ARE NOT CONTROLLABLE
In Addition to Above (A)
Order to blow emergency `ALERT Siren (30 second continuous).
Organize Fire fighting / rescue team members to control the
Incident.
Take stock of situation if required shut down the plant /
process in affected area.
Call Fire Brigade if situation demands.
Evacuate affected area.
Organize head count of the plant.
Act as INCIDENT CONTROLLER till such time senior person takes
charges as
indicated in Emergency organisation
NOTE: 1) Messenger will wait until such time Security Officer
arrives.
2) Also inform Telephone Operator.
SECURITY OFFICER / GUARD
DOs
Do not allow any vehicle to come inside the factory.
Do not entertain any outside call except for emergency purpose.
Do not allow visitors to move around.
Inform all key persons about location and type of emergency.
Follow this sequence Inform concerned HOD/Section Head, Main
Site Controller,
Main Incident Controller & Safety Officer and other KEY
persons.
Inform Main Site Controller about Government visitors, if
any.
DONTs
Do not entertain any outside call except for emergency
purpose.
Do not allow visitor to move around, from reception.
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SECURITY GUARD
DOs
Immediately report at Security Gate in shortest possible
time.
Follow instructions of Officer In-charge.
Assist in controlling emergency.
Assist in controlling contractors, vehicle movement and mob.
Assist in cordoning off the area.
Take note of wind direction while approaching emergency
site.
Render all possible help for controlling overall situation.
DONTs
Do not leave the site unless asked to do so.
EMERGENCY VEHICLE DRIVER
DOs
Immediately start vehicle and reach rescue squad assembly point
(near security
gate).
Rescue squad members to emergency site.
Take vehicle near to emergency site as directed.
Take note of wind direction.
Reverse the emergency vehicle for quick transports of injured,
if any.
Keep vehicle engine running. Always be on Drivers seat of the
vehicle.
Take the injured to the hospital as directed.
DONTs
Do not leave the vehicle.
Do not take the vehicle very near to the site.
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INCIDENT CONTROLLER
DOs
Approach emergency site as early as possible taking note of wind
direction.
Take stock of situation.
Interact with all concerned departments as the situation
demands.
Keep Main Site Controller informed about the latest emergency
situation on
continuous basis.
SITE CONTROLLER
DOs
Will approach emergency site immediately / Assess the
situation.
Consult Incident Controller.
Consult advising Committee Members.
Instruct Main Incident Controller.
Communicate to higher ups and Govt. authorities, if
required.
Decide upon need for evacuation and blow `Disaster Siren.
After getting satisfied with the situation, give instruction to
blow ALL CLEAR Siren.
DONTs
Do not instruct to blow ALL CLEAR siren unless the situation is
fully under control.
Dont evacuate the entire plant unless the situation demands.
FIRE FIGHTING SQUAD ON HEARING SIREN
DOs
Inform fellow employees/Officers.
Report to Fire Squad Assembly point.
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Find out emergency location.
Approach emergency site immediately.
Take quick action as per the instructions from Incident
controller.
Bring emergency under control as early as possible.
DONTs
Do not leave process/equipment inUNSAFE CONDITION.
Do not leave emergency site unless ALL CLEAR siren blown.
Do not use improper fire extinguisher.
Do not be panicky.
RESCUE SQUAD
DOs
Report to assembly point near Gate.
Get in touch with security about location and type of
emergency.
Approach emergency site quickly with Breathing Apparatus set and
First Aid box.
Get in touch with incident controller.
Follow instructions of Incident controller.
Render first aid to the injured, hospitalize, if required.
Accompany him to hospital and assist Doctor / Nurse.
Search for missing person in that area, if required.
Help in head count.
ALL GENERAL EMPLOYEES EXCEPT THOSE WHO ARE IN EMERGENCY
ORGANIZATION ON HEARING SIREN
DOs
Be alert and be available if required.
Wait for further instructions.
Bring down the process/plant/equipment in SAFE CONDITION in case
of DISASTER
siren as per instructions from Incident Controller.
Approach respective safe assembling points route as taking note
of wind direction.
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Help in taking roll call.
After hearing ALL CLEAR, go back to the departments.
Start the work again after setting instruction from Incident
controller.
DONTs
Do not be panicky. Do not run.
Do not approach emergency site unless asked for.
Do not engage telephone except for emergency purpose. Keep lines
free.
TECHNICAL TEAM: ENGINEERING DEPARTMENT / ENVIRONMNET, SAFETY
ANDHEALTH DEPARTMENT ON HEARING SIREN
DOs
Be available in Engineering Department at respective location
for any help.
Approach emergency site with required with tools and equipments
and should work
on instructions of Incident controlle.
Help Incident Controller to provide technical assistance.
Isolate lines, process equipments, if required by Incident
Controller.
Provide emergency equipments like Fire Extinguisher, Hoses,
etc., if asked by
Incident Controller.
Provide stop gap arrangements as per the requirement of Incident
Controller.
Carry out electrical isolation of area as per instructions from
Incident Controller.
ADVISORY COMMITTEE (ALL DEPARTMENT HEADS)
DOs
Approach emergency site as early as possible.
Render advise to Main Incident Controller and Main Site
Controller to control
emergency.
COMMUNICATION COMMITTEE (P&A)
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DOs
Consult Main Site Controller
Give necessary instructions to security / Telephone
Operator.
Give instruction to Security to control traffic / crowd.
Look after injured, communicate with the family members, if
situation demands.
Arrange transportation, if required.
DONTs
Do not communicate to any one or brief press without permission
of Main Site
Controller.
GENERAL INTRUCTIONS
DOS
Stop work at height. / Stop all hot works.
Stop all vessel entry.
Take note of wind direction.
On hearing Disaster Siren evacuates as per evacuation route
without running and
panicky and assembles at respective safe Assembly Points.
DONTs
Do not use telephone except for emergency purpose.
Do not start work at height, vessel entry, hot work unless
permit conditions are
verified.
Do not allow unauthorized person to approach emergency site.
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--------------------
ANNEXURE A
BRIEF DESCRIPTION OF THE MANUFACTURING PROCESS
BRIEF MANUFACTURING PROCESS OF ----------------------
Stage I:
Stage II:
Stage III:
Stage IV:
BRIEF MANUFACTURING PROCESS OF ---------------------
Stage I:
Stege II:
Stage III:
BRIEF MANUFACTURING PROCESS OF ---------
Stage I:
Stage II:
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BRIEF MANUFACTURING PROCESS OF -----------------
----------------------------
ANNEXURE B
TELEPHONE NUMBERS OF POLICE, FIRE BRIGADE, HOSPITALS, AND
OTHER OUTSIDE EMERGENCY SERVICES
POLICE DEPT-
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FIRE BRIGADE
M.S.E.B. OFFICE: -
GRAMPANCHAYAT OFFICE :-
HOSPITALS :-
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------------------------------
ANNEXURE C
TELEPHONE NUMBERS AND ADDRESSESOFKEY PERSONNEL
LIST OF KEY PERSONS
NAME RESIDENCE TEL. NO.
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------------------------------
ANNEXURE D
MUTUAL AID SCHEME MEMBERS
MUTUAL AID RESPONSE GROUP
NAME COMPANY OFFICE PHONE
------------------------------
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ANNEXURE E
LIST OF FIRE AND RESCUE SQUAD MEMBERS
FIRE FIGHTING SQUAD FIRST AIDER(RESCUE SQUAD)
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------------------------------
ANNEXURE F
EMERGENCY CONTROL SYSTEM FIRE HYDRANT SYSTEM
An underground Fire Hydrant System has been installed in the
plant with rings around all
blocks to achieve maximum coverage. Water reservoir of 135m3
(Hydrant tank) + 20 m3
(MIDC Storage tank with feed from the MIDC water supply has been
provided at highest
point in the plant. Following are the details of the system.
a. Water Reservoir- 135+20 m3.
b. Type of Hazard- Pharamaceutical, Ordinary Hazard.
c. Design Code-TACs Fire Protection Manual.
d. Total no. of Fire Hydrant including landing Values,
Watermonitor-19 Nos.
e. Automatic Operation-Jockey pump of 10.8 m3/[email protected]
capacity
with pressure switches.
f. Stand by arrangement-Diesel Generator with AMF control
panel.
g. Nos of Hose Boxes-External-18 nos
h. Nos of Hoses-36
i. Nos of Nozzles-15 mm bore-17 nos.
j. Hydrant flexible rill-6 nos.
k. Electric Driven main pump - 70 M head 38 M3/hour flow at 7
kg./cm
2
-No 1
l. One Jockey pump provided of capacity 23 m3 /hr 91 M Head.
m. Auto changeover switch operated DG set System ensures that
the
hydrant pump is kept working.
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--------------------------------------------
ANNEXURE GFIRE EXTINGUSHER
List of Fire Extinguishers
The company has trained personnel for fire fighting and its
intends to improve the firefighting skills of their employee by
conducting training on Fire fighting. There are 44portable fire
extinguishers, the break-up of which is as under: -
Sr.No. Area Location Type Capacity1 DCP 5 KG
2 DCP 5 KG
3 DCP 5 KG
4 FOAM 50 Lit
5 DCP 5 KG
6 DCP 5 KG
7 DCP 5 KG
8 DCP 5 KG
9 DCP 5 KG
10 DCP 5 KG
11 FOAM 50 Lit
12 DCP 5 KG
13 DCP 5 KG
14 FOAM 50 Lit
15 DCP 5 KG
16 CO2 3.0 KG
17 DCP 5 KG
18 CO2 6.5 KG
19 DCP 10 KG
20 CO2 3.0KG
21 CO2 3.0 KG
22 DCP 5 KG
23 DCP 10 KG24 FOAM 50 Lit
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25 DCP 5 KG
26 CO2 6.5 KG
27 DCP 5 KG
28 DCP 5 KG
29 CO2 3.0 KG
30 DCP 5 KG
31 DCP 5 KG
32 DCP 5 KG
33 CO2 3.0 KG
34 CO2 3.0 KG
35 DCP 5 KG
Sr.No. Location Type Capacity36 CO2 3.0 KG
37 DCP 5 KG
38 DCP 5 KG
39 DCP 5 KG
40 DCP 5 KG
41 CO2 3.0 KG
42 FOAM 9 KG
43 DCP 5 KG
44 DCP 5 KG
Total Fire Extinguisher:
Sr. NoTypes of Extinguisher Total Nos.
1 DCP 29
2 CO206
3 Foam 09
Sand Buckets: 05 Nos
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------------------------------
ANNEXURE H
LIST OF PERSONAL PROTECTION EQUIPMENT
LIST OF PERSONEL PROTECTIVE EQUIPMENTS
ITEM NOS.
Safety Helmet 100
Safety Goggles 20
Safety Shoes 52
PVC Apron 05
Asbestos Gloves 05
Rubber Gloves 50
Eye Wash Fountain 05
Gum Boots 02Cloth Mask 10
Safety Belt 04
Organic Vapor Mask 10
Self Contained Breathing Apparatus 01
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ANNEXURE I
FIRST AID MEDICAL FACILITIES.
The company has provided First AID boxes at security office.
Following are the
contents of First aid.
1. Tincture iodine.
2. Eye wash solution.
3. Burnol
4. Soframycin (ointment)
5. Sterilized cotton wool.
6. Band-aid.
7. Antiseptic Solution (Dettol)
8. Bandage.9. Paracetamol tablets.
10. Iodex.
11. Pair of scissor.
The company has got its own transport facilities to take the
injured to the hospital.
The nearest hospitals are _________________________________
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ANNEXURE J
List of some Hazardous Chemicals and Action
Page 34 of 49
Sr.
No
Name Boiling points Flash
points
Explosive limits TLV
in
PPM
Action to be taken
Lower %VOL
Upper% VOL
1 Methanol 64 11 6 36 200 Use AFFF For
extinguishing fire.
Use SCBA and Other
PPE.
2 Toluene 110 4 1.3 6.8 100 Use AFFF For
extinguishing fire.
Use SCBA and OtherPPE
3 MDC 39.8 - 12 23 50 Use SCBA and Other
PPE
4 Ethyl
Acetate
77 -4 2 11.5 400 Use AFFF For
extinguishing fire.
Use SCBA and Other
PPE
5 IPA 82 12 2 12 400 Use AFFF For extinguishing fire.
Use SCBA and Other
PPE
6 Ethanol 77 13 3.3 19 100
0
Use AFFF For
extinguishing fire.
Use SCBA and Other
PPE
7 n-Hexane 68 -21 1.1 7.5 50 Use AFFF For
extinguishing fire.
Use SCBA and Other
PPE
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List of some Hazardous Chemicals and Action
ANNEXURE K
Page 35 of 49
SrNo
Name Boilingpoints
Flashpoints
Explosivelimits
TLVin
PPM
Action to be taken
Lower
%
VOL
Upper
%
VOL
8 DMF 153 58 2.2 15.2 10 Use AFFF For
extinguishing fire.
Use SCBA and
Other PPE9 Acetone 56.5 -20 2.5 12.8 500 Use AFFF For
extinguishing fire.
Use SCBA and
Other PPE
10 THF 66 -14 2 11.8 200 Use AFFF For
extinguishing fire.
Use SCBA and
Other PPE
11 Di-ethyl ether 35 -45 1.9 36 400 Use AFFF For
extinguishing fire.
Use SCBA and
Other PPE
12. TriethylAmine 90 -9 1.2 8 10 Use AFFF For
extinguishing fire.
Use SCBA and
Other PPE
13 Dimethylamine 7.4 -6 2.8 14.4 10 Use AFFF For
extinguishing fire.
Use SCBA and
Other PPE
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SCENARIO BASED EMERGENCY ACTION
Based on the reactions involved during the production process
and the raw
material involved the possible hazards are indentified. The
action for the
emergency situation is given.
Product Name
Sr.
no
Type of Reaction Critical raw material Possible Hazards
Action
1 Oximination Methylene chloride
Liq. Ammonia
Hydroxylamine
hydrochloride
Triethylamine
Methanol
Irritating to eyes, skin
with burning pain
etching and redness.
Gastrointestinal
irritation with nausea,
vomiting and diarrhea,
may cause kidney
damage. CNS
depression, followed
by headache, dizziness,
drowsiness.
Ammonia vapors are
highly irritant and
corrosive.
Harmful if swallowed,
inhaled or absorbed
through skin, causes
burn to any area of
contact.
Corrosive and irritating
to the eyes, skin, all
living tissues and
respiratory tract.
Flammable liquid,
causes severe eye
Immediately flush
with large amount of
water; if inhaled
remove to fresh air.
Immediately flush
with large amount of
water. Use respiratory
protection.
Immediately flush
with large amount of
water to any area of
contact.
Immediately flush
with large amount of
water to any area of
contact.
Follow fire action in
case of fire.
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irritation, may cause
blindness if swallowed;
may cause skin
irritation, CNS
depression, and liver,
kidney damage.
Immediately flush
with large amount of
water to any area of
contact.
2 Silylation 2-Methoxy propane
Hexamethyldisilazane
Pyridine
hydrobromide
Toluene
Sodium carbonate
Flammable liquid and
vapor may cause flash
fire, harmful if
swallowed, inhaled or
absorbed through skin,
causes burn to any area
of contact.
Highly flammable,
corrosive and harmful
to any area of contact.
Irritant to eyes and
skin.
Keep away from heat
and ignition source;
harmful if swallowed,
inhaled or absorbed
through skin; causes
burns to any area of
contact.
May cause eye burn;
irritation to skin and
respiratory tract;
harmful if swallowed
Follow Fire action in
case of Fire.
Immediately flush
with large amount of
water to any area of
body contact.
Follow Fire action in
case of Fire.
Immediately flush
with large amount ofwater.
Immediately flush
with large amount of
water.
Follow Fire action in
case of Fire.
Immediately flush
with large amount of
water.
Immediately flush
with large amount of
water.
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or inhaled.
3 Methylation Methyl iodide
Dimethylsulfoxide
Dimethylamine (40%)
Potassium hydroxide
Potentially fatal if
inhaled; harmful if
swallowed, respiratory
tract irritation, skin
irritation, eyes irritation
and CNS depression.
Corrosive and irritating
to the eyes and skin, all
living tissues and
respiratory tract.
Extremely flammable
liquid and vapor may
cause flash fire,
harmful if swallowed,
inhaled or absorbed
through skin, causes
burn to any area ofcontact.
May causes burn to the
eyes, skin, respiratory
and gastrointestinal
tract.
If breathing is difficult
oxygen should be
administered by
qualified personal and
wash with water if
contact with skin and
eyes.
Immediately flush
with large amount of
water.
Follow Fire action in
case of Fire.
Immediately flush
with large amount of
water.
Immediately flush
with large amount of
water.
4 Deprotection Sodium bisulfite
Formic acid
Harmful if swallowed,
may cause irritation.
Corrosive and irritating
to the eyes, skin, all
living tissues and
If swallowed, induce
vomiting immediately
after giving two glass
of water.
Immediately flush
with large amount of
water.
Immediately flush
with large amount of
water.
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Ethanol
Sodium Hydroxide
respiratory tract.
Flammable liquid
May causes burn to the
eyes, skin, respiratory
and gastrointestinal
tract.
Follow fire action in
case of fire.
Immediately flush
with large amount of
water.
2. Product Name
Sr.
no
Type of
Reaction
Critical raw
material
Possible Hazards Action
1 Cycloalkylation 1,3-
dibromopropane
DMSO
Toluene
Methylene
chloride
Flammable liquid and
vapor; harmful if
swallowed or inhaled;
affects CNS; causes
irritation to skin, eyes
and respiratory tract.
Corrosive and irritating
to the eyes and skin, all
living tissues and
respiratory tract.
Keep away from heat
and ignition source;
harmful if swallowed,
inhaled or absorbed
through skin; causes
burns to any area of
contact.
Irritating to eyes, skin
with burning pain
etching and redness.
Gastrointestinal irritation
Follow Fire action in case
of Fire. Remove to fresh
air; If not breathing give
artificial respiration; if it is
difficult give oxygen. Give
large amount of water to
drink. Immediately flush
with water.
Immediately flush with
large amount of water to
any area of contact.
Follow Fire action in case
of Fire. Immediately flush
with large amount of
water.
Immediately flush with
large amount of water; if
inhaled remove to fresh
air.
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4-Chloro
phenylacetonitrile
with nausea, vomiting
and diarrhea, may cause
kidney damage. CNS
depression, followed by
headache, dizziness,
drowsiness.
Hazardous in case of
skin contact, eye contact
or inhalation, severe
exposure can result in
death.
Immediately flush with
plenty of water. If inhaled
remove to fresh air. If not
breathing give artificial
respiration.
2 Tandem
Grignard
reduction
Bromomethyl
propane
Magnesium metal
Isopropyl alcohol
Flammable liquid and
vapor; harmful if
swallowed or inhaled;
affects CNS; causes
irritation to skin, eyes
and respiratory tract.
Highly inflammable, and
harmful if swallowed or
inhaled. Irritating to
eyes, nose, throat, skin
and CNS; over exposure
to the vapor may cause
headache, drowsiness.
Flammable liquid;
harmful if swallowed or
inhaled. Irritating to
eyes, nose, throat, skin
and CNS; over exposure
to the vapor may cause
headache, drowsiness.
Keep away from heat
Follow Fire action in case
of Fire. Remove to fresh
air; If not breathing give
artificial respiration; if it is
difficult give oxygen. Give
large amount of water to
drink.Follow fire action in case
of fire. Immediately flush
with large amount of
water.
Follow fire action in case
of fire. Immediately flush
with large amount of
water.
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Tetrahydrofuran
Ethyl acetate
Sodium
borohydride
Hexane
and ignition source;
harmful if swallowed,
inhaled or absorbed
through skin; causes
burns to any area of
contact.
Flammable liquid and
vapor. Harmful if
swallowed or inhaled.
Affects CNS; causes
irritation to skin, eyes
and respiratory tract.
Highly flammable, toxic,
contact with water
liberate flammable gases.
Toxic in contact with
skin and if swallowed,
very toxic by inhalation;
causes burns and react
violently with water.
Flammable liquid;
harmful if swallowed or
inhaled. Irritating to
eyes, nose, throat, skin
and CNS; over exposure
to the vapor may cause
headache, drowsiness.
Follow Fire action in case
of Fire. Immediately flush
with large amount of
water.
Follow Fire action in case
of Fire. Remove to fresh
air; If not breathing give
artificial respiration; if it is
difficult give oxygen. Give
large amount of water to
drink. Immediately flush
with water.
In case of skin, eyes
contact flush with copious
amount of water. Follow
fire action in case of fire.
Follow fire action in case
of fire. Immediately flush
with large amount of
water.
3 Methylation Formic acid Corrosive and irritating
to the eyes, skin, all
living tissue and
respiratory tract.
Immediately flush with
large amount of water.
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Formaldehyde
IPA. HCl
Poison, danger; suspect
cancer hazard; may
cause cancer; vapor
harmful if inhaled or
absorbed through skin.
Causes irritation to skin,
eyes, and respiratory
tract; Strong sensitizer,
causes blindness if
swallowed; flammable
liquid and vapor.
Flammable liquid;
harmful if swallowed or
inhaled. Irritating to
eyes, nose, throat, skin
and CNS; over exposure
to the vapor may cause
headache, drowsiness.
Follow Fire action in case
of Fire. Remove to fresh
air; If not breathing give
artificial respiration; if it is
difficult give oxygen. Give
large amount of water to
drink. Immediately flush
with water.
Follow fire action in case
of fire. Immediately flush
with large amount of
water.
3. Product Name
Sr.
no
Type of Reaction Critical raw
material
Possible Hazards Action
1 Cyanation 2,3-Dichloro
benzoyl
chloride
Cuprous
cyanide
Corrosive
Poison; Danger; may be
fatal if swallowed, inhaled
or absorbed through skin.
Contact with acid liberates
poisonous gas; causes
severe eye irritation and
possible burn. Affect
In case of contact wash
off immediately with
water.
A cyanide antidot kit
should be available in
any cyanide work area.
In case of cyanide
poisoning start first air
treatment and flush skin
with plenty of water.
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Acetonitrile
Toluene
Hexane
blood, cardiovascular
system, CNS and thyroid.
Keep away from heat and
ignition source; harmful if
swallowed, inhaled or
absorbed through skin;
causes burns to any area
of contact.
Keep away from heat and
ignition source; harmful if
swallowed, inhaled or
absorbed through skin;
causes burns to any area
of contact.
Flammable liquid;
harmful if swallowed or
inhaled. Irritating to eyes,
nose, throat, skin and
CNS; over exposure to the
vapor may cause
headache, drowsiness.
Follow Fire action in
case of Fire.
Immediately flush with
large amount of water.
Follow Fire action in
case of Fire.
Immediately flush with
large amount of water.
Follow fire action in
case of fire.
Immediately flush with
large amount of water.
2 Condensation and
cyclisation
Sulfuric acid Vapor may cause pulm
irritation and eye
irritation; severe chem.
burn to eyes and skin
Remove to fresh air,
Resuscitate if not
breathing; flush with
plenty of water.
4. Product Name
Sr.
no
Type of Reaction Critical raw
material
Possible Hazards Action
1 Dehydroiodination Iodine Vapor severely irritate and
can burn mucous membrane
and respiratory tract; excess
tears, tightness in chest,
headache; inflammation of thenasal mucous, bronchitis,
Follow Fire action in
case of Fire. Remove to
fresh air; If not
breathing give artificial
respiration; if it isdifficult give oxygen.
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Pyridine
Methanol
HCl
rapid heart beat, diarrhea and
wt. loss.
Irritation of eyes, skin,
respiratory tract, chest pain,
difficulty in breathing, CNS
effects like headache,
dizziness, nausea and
vomiting, redness or burns of
eyes/skin lever or kidney
damage.
Flammable liquid, causes
severe eye irritation, may
cause blindness if swallowed;
may cause skin irritation,
CNS depression, and liver,
kidney damage.
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. Extreme heat of
contact with metal can release
flammable hydrogen gas.
Vapor may cause pulm
Give large amount of
water to drink.
Immediately flush with
water. Iodine stains can
be removed by
immediate washing
skin by 5% sodium
thiosulphate solution.
Inhalation remove to
fresh air, Resuscitate if
not breathing; flush
with plenty of water.
Follow fire action in
case of fire.
Immediately flush with
large amount of water
to any area of contact.
Remove to fresh air. If
not breathing give
artificial respiration; if
it is difficult give
oxygen. Do not induce
vomiting. Give large
amount of water to
drink. In case of
contact, immediately
flush with plenty of
water. Follow fireaction in case of fire.
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Sulfuric acid
Sodium
thiosulphate
Sodium
hydroxide
Hesperidin
irritation and eye irritation;
severe chem. burn to eyes and
skin.
Inhalation, irritation to
mucous membrane, mild
irritation of eyes and skin.
May causes burn to the eyes,
skin, respiratory and
gastrointestinal tract.
May cause skin and eye
irritation; may cause
respiratory and digestive tract
irritation.
Remove to fresh air,
Resuscitate if not
breathing; flush with
plenty of water.
Flush with plenty of
water.
Immediately flush with
large amount of water.
Immediately flush with
large amount of water
5. Product Name
Sr.
no
Type of
Reaction
Critical raw
material
Possible Hazards Action
1 Condensation Methanol
Dimethyl
Formamide
Acetic acid
Flammable liquid, causes severe
eye irritation, may cause
blindness if swallowed; maycause skin irritation, CNS
depression, and liver, kidney
damage.
Poison; danger, combustible; may
be fatal if swallowed; inhaled or
absorbed through skin. Keep
away from heat, sparks and flame.
Irritation of breathing vapors.
Strongly corrosive and causes
serious burns. Lachrymator; may
cause irritation to eyes, skin and
respiratory tract.
Follow fire action in
case of fire.
Immediately flush withlarge amount of water
to any area of contact.
Inhalation remove to
fresh air, Resuscitate if
not breathing; flush
with plenty of water.
Immediately flush with
plenty of water.
Remove from exposure
and move to fresh air.
If breathing is difficult,
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Hydrochloric
acid
Toluene
Chloromethyl
aniline
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. Extreme
heat of contact with metal can
release flammable hydrogen gas.
Keep away from heat and ignition
source; harmful if swallowed,
inhaled or absorbed through skin;
causes burns to any area of
contact.
May cause eye, skin, digestive
tract irritation, liver and kidney
damage
give oxygen.
Remove to fresh air. If
not breathing give
artificial respiration; if
it is difficult give
oxygen. Do not induce
vomiting. Give large
amount of water to
drink. In case of
contact, immediately
flush with plenty of
water. Follow fire
action in case of fire.
Follow Fire action in
case of Fire.
Immediately flush with
large amount of water.
Immediately flush with
plenty of water.
Remove from exposure
and move to fresh air.
If breathing is difficult,
give oxygen.
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ANNEXURE L
EMERGENCY ORGANIZATION CHART
Fire
fighting
Squad
First aid
Squad
P & .A.
Dept
Engineering Security
Dept.
EHS Manager Shift In
charge
Site controller
Incident Controller
