Onsite Emergency Preparedness Plan Saswad Final

On –Site Emergency Preparedness Plan-Saswad Factory

Document No. COR/HRM/EPP/02

Rev. No. & Date 03; 23/01/2011

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Prepared by – Safety Officer Approved by – HOD HRM EHS/MR/F/37

ON-SITE EMERGENCY PREPAREDNESS PLAN

FOR

KIRLOSKAR PNEUMATIC CO. LTD, PLANTSASWAD PUNE-412301



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Contents 1. INTRODUCTION

2. DISTRIBUTION LIST

3. REVISION STATUS AND APPROVAL STATUS OF THE PLAN

4. COMPANY PROFILE

5. OBJECTIVES OF THE PLAN

6. REQUIREMENTS OF EMERGENCY PLAN

7. DETAILS FURNISHED IN THE ON-SITE EMERGENCY PLAN BY:-

8. KEY PERSONNEL OF THE ORGANIZATION AND RESPONSIBILITIES

ASSIGNED TO THEM IN CASE OF AN EMERGENCY.

9. EXTERNAL AGENCIES CONTACT DETAILS INVOVED DURING

EMERGENCY

10. INFORMATION ON THE PRELIMINARY HAZARD ANALYSIS

11. DETAILS ABOUT SITE

12. EMERGENCY CONTROL ROOM (ECC). –

13. DESCRIPTION OF HAZARDOUS CHEMICALS AT THE PLANT SITE.

14. LIKELY DANGERS TO THE PLANT

15. POTENTIAL HAZARD CASES CONSIDERED

16. GENERAL GUIDELINES FOR EMPLOYEES

17. MEASURES TO BE EMPLOYED FOR MEETING THE OBJECTIVES

18. HAZARD CONTROL MEASURES IN CASE OF EMERGENCIES

19. EMERGENCY ACTION PLAN

20. IDENTIFIED EMERGENCY & ACTION PLAN

21. EMERGENCY PERSONNEL'S RESPONSIBILITY DURING DAY SHIFT

22. EMERGENCY PERSONNEL'S RESPONSIBILITIES DURING NIGHT SHIFTS

AND HOLIDAYS.

23. COMMUNICATION FACILITIES

24. DETAILS OF OTHER SERVICES AVAILABLE ONSITE

25. METHOD OF REPORTING EMERGENCY

26. EMERGENCY ASSEMBLY POINTS:



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27. EMERGENCY ACTIONS

28. SHUT DOWN PROCEDURE

29. POST EMERGENCY

30. CORRECTIVE ACTIONS 31. REHEARSAL / SIMULATION /MOCK DRILL



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KIRLOSKAR PNEUMATIC CO. LTD Saswad Plant PUNE 412301.

ON SITE EMERGENCY PLAN

1. INTRODUCTION The ultimate aim was to use the hazardous processes, materials under control in safe way and try to minimize the health, environment damage in case of an accident/ dangerous occurrence. A major emergency in a factory is one, which has the potential to cause a serious injury, or loss of life. It may cause extensive damage to property and serious disruption both inside and outside the factory. It would normally require the assistance of outside emergency services to handle it effectively and timely. Although the emergency may be caused by number of different factors like plant failure, human error, earthquake, vehicle crash, fire, explosion or toxic release. Prevention of accident through superior design, operation, maintenance and inspection, achieving all these will reduce the risk of an accident, but it will not eliminate all together, complete safety is hard to achieve and an essential part of major hazard control is concerned with mitigating the effects of a major accident. An important element of mitigation is emergency planning. Emergency planning means recognizing that accidents are possible, assessing the consequences of such accidents and deciding an emergency procedure, both on-site & out-site, that would need to be implemented in the event of an emergency. It is an aspect of safety management. On site emergency management planning is the responsibility of site management. On these requirements of Emergency Preparedness, at KPCL we have carried out this exercise by adhering the guidelines framed under The Maharashtra Factories (Control of Industrial Major Accidents Hazards) Rules, 2003

2. DISTRIBUTION LIST

The protected copy (read only) of Onsite plan is available to all employees on intranet (Shashwat)



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3. REVISION STATUS AND APPROVAL STATUS OF THE PLAN

No. Document No. Brief description of revision Revised to Effective date

1 Plant wise not identified EHS/MR/F/37/REV.00 1-Nov-08

2 EHS/MR/F/37/REV.00 Site plans are added to the document EHS/MR/F/37/REV.01 1-Jun-10

3 EHS/MR/F/37/REV.01

Emergency Action Plan

Identified Emergency & action plan

Method Of reporting Emergency

Emergency assembly Points:

Emergency Actions

Shutdown Procedure

Post Emergency actions

Corrective Actions

Simulation Mock drill procedure

COR/HRM/EPP/02 15-Oct-10

4 COR/HRM/EPP/02

EPR-Emergency Specific procedures for Heat Treatment furnace at Saswad included

COR/HRM/EPP/02, rev. 03 23-Jan-11



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4. COMPANY PROFILE

(a) About the Company -. The company is located at Kirloskar Pneumatic Co. Ltd Near Waghire College Pune-Saswad road Saswad, Tal-Purandhar. Dist-Pune 412301Total strength of the company is around 150 including managerial staff. Main activity of the company is manufacturing of Air Conditioning compressors and various types of PGS projects. Operations are carried out in following major sections- 1. Fabrication Shop 2. Machine Shop 3. Assembly Shop & Testing 4. Painting & Dispatch 5. Project Assembly & testing

Manpower:

Shift-wise Employees Contractors Total

Shift I 100 25 125 Shift II 34 07 41 Shift III NA NA NA

FACTORY SURROUNDINGS: North Side: Electronica Machine tools South Side: Open area, Kirloskar Chillers & Saswad Town East Side: Open area, Highway Pune – Saswad. West Side: Open Land. 5. OBJECTIVES OF THE PLAN On-Site emergency preparedness plan has the following objectives:

Safeguard lives and property at site and in its vicinity area. Contain the incident and bring it under control; Minimize damage to lives, property and environment; Rescue and treat casualties; Evacuate people to safe areas;

6. REQUIREMENTS OF EMERGENCY PLAN

Pre-Emergency

Pre – Emergency means the preparatory stage of the plan. If the planning period and it should come out to ensure that the prepared plan contains all required



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provisions and details of facility to handle and to contain the emergency situation successfully. The unit has to consider maximum and possible worst scenario for emergency purpose while planning. The unit has to develop and maintain the essential facilities, so that the emergency can be controlled and the damages are minimized in the shortest period with proper use of all available resources.

The unit should be duly prepared and ready all the time to encounter any possible emergency, while it may strike or not. Being a Heavy Engineering unit and knowing the hazards of the chemical, stored, handled or processed in the factory, the quick response action must be created within unit.

The structure of the plan may vary depending on the number of employees, materials, process, availability of recourses, location of site, size and complexity of the unit. It should ensure to work out a plan with possibilities of various emergencies with likely to arise within unit. Further the periodical rehearsal is also to be carried out to check and examine the effectiveness, awareness and preparedness of the plan as well as services. The emergency planning is not a substitute for good design, plant operating and maintenance practices. Therefore, the Onsite Emergency Action Plan must be followed to avoid emergency

CHECK SCHEDULE

Check all the fire – fighting equipment’s, installations and machineries for their conditions, physical availability, work ability and take necessary actions for replacement and maintenance, if required. Check resources of water. Keep all emergency and essential Telephone Nos. with contact persons, suppliers for the same handy. Contact details may be displayed on the boards installed at prominent locations in the plant and offices. Maintain the coordination with other fire – services.

Personnel Protective Equipment

Check all the personnel protective equipment’s provided at different places for their condition sound working, maintenance’s and replacement, whenever required. Also keep the note of sufficient stock of required personnel protective equipments.

Safety System

Check the working of all safety devices, interlock systems and ensure that safety- guards, railings, fencing, etc. are in position. The safety equipment should always be kept available in working condition. The safety motivation and safety training is the continuous process and it is necessary to arrange such type of training



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periodically. Check the monitoring instruments, wherever provided, whether they are indicating correct parameters or not.

Preventive Maintenance

A scheduled periodical preventative maintenance and inspection of the plants, Pressure vessels, centrifuges, equipment’s, storage tanks, air compressors, D.G. Sets etc. are as per laid down procedures and check that records are maintained properly. Check the test, examination and certification have been carried out within reasonable period.

Training

By imparting an effective training to the plant supervisors, inspectors, and education and training of the workers from time to time, the awareness is to be kept alive all the time to ensure safety awareness, preparedness for emergency situations, good housekeeping, discipline, etc. Display of safety slogans, operative instructions and motivation for safety should be made part of the company’s normal activities. All the persons earmarked for the emergency services are to be trained to respond to the emergency.

Monitoring The Environment Constant and rigorous monitoring of environment is required for detection of a possible damage or a risky situation arises.

Potentiality on Liaison

Keep the constant liaison with nearby industries, fire services, police department, medical services, statutory authorities, district administration, for pre emergency situation. Liaison with local Crisis Group and District Crisis Group should also be maintained.

Exercise / Mock Drill / Rehearsal

Organize the periodical mock drill / rehearsal as per suggested format by creating an emergency situation so as to verify preparedness and awareness as well as shortcomings on the part of the person to overcome the same. Provide sufficient time prior to mock drill to the emergency services and public for proper response to exercise and provide training also. Record the deficiencies of the system during the trial and take appropriate actions to improve the efficiency of the plan in terms of preparedness and response.

Maintenance of Records



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Keep the records of the monitoring conditions, safety systems, storage levels, process condition, etc. and maintain the log- books, registers etc. Keep the M.S.D.S. and onsite emergency plan with required details.

Emergency Control Room The equipped Emergency Control Room should be in working order. The plant layout maps, drawing, storage details, Material safety Data Sheets (MSDS), emergency operations, manuals etc. should be kept and should be updated continuously. List of essential telephone Nos. is also maintained up to date. The senior and expert person should be posted as in charge of the control room.

Command & Control

The organization chart, for the emergency plan has been given which explains the chart of command, channel of information flow, and actions as required during the emergency. The single organizational structure has been created on striking emergency and the same shall be continued till the emergency over. The Shift Supervisor shall take the initial charge as incident controller; he will be coordinating with various agencies effectively to combat the situation. The security office room will be used as emergency control Room. The security gate will be used as Assembly point. The Factory Manager will act as site main controller for the unit. On arrival, he will supervise all activities with the help of asst. Plant incharge. The duties & responsibilities have been defined as per below.

WARNING ALARM AND SAFETY AND SECURITY SYSTEMS. The Emergency Siren system is installed at Terrace of Canteen Building (covering the entire site), the actuating control panel is at ECC (Time Office), personnel at Time office are trained to actuate the Emergency Siren. Incase of electric failure manual Emergency Siren is provided at Security Maingate.

CODIFICATION OF SIRENS

Sr. SIRENS INDICATES AUTHORITY

1. 30 SECONDS

Continuous Whelming

Sound

ON SITE

EMERGENCY (ALERT)

SITE CONTROLLER

2. 30 SECONDS

Continuous sound

EMERGENCY

CONTROLLED

SITE CONTROLLER



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(ALL CLEAR)

NOTE:

EMERGENCY SIREN TO BE SOUNDED ONLY IF REQUIRED

ALL EMPLOYEES IN AREAS OTHER THAN AFFECTED TO CONTINUE

WORK UNLESS DISASTER SIREN IS BLOWN.

NO EMERGENCY ORGANIZATION MEMBER WILL LEAVE THE EMERGENCY

SPOT UNLESS `ALL CLEAR’ SIREN BLOWN.

7. DETAILS FURNISHED IN THE ON-SITE EMERGENCY PLAN BY:-

NAME & ADDRESS OF THE PERSON FURNISHING THE INFORMATION.

Name: Mr. Sandeep R Kulkarni (Factory Manager-Overall site Incharge) Works: Plot No-1, Hadapsar Industrial estate pune-13.

Residence: Flat No- A –1/601 Prasad Nagar Wadgaon Sheri Pune-411014



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8. KEY PERSONNEL OF THE ORGANIZATION AND RESPONSIBILITIES ASSIGNED TO THEM IN CASE OF AN EMERGENCY.

NAME DESIGNATION/DEP

T RESPONSIBILITY ASSIGNED

INTER. TEL. No.

RESID.. TEL. No.

D R SHINDE DGM-MFG SITE CONTROLLER 9881460092

A K PATIL HOD ADMIN SITE CONTROLLER 2001 9822978091

N M BAPAT SAFETY OFFICER INCIDENT CONTROLLER 2907 9822978093

S S KADBANE PLANT ENGG INCIDENT CONTROLLER 2203 9689943969

A S CHHAPKHANE ACR- MFG INCIDENT

CONTROLLER 2101 9850969431

SAGAR KHALADKAR ACR-MFG INCIDENT

CONTROLLER 2101 9823969345

M MSHINDE DISPATCH INCIDENT CONTROLLER 2201 9922970216

S M JOSHI STORES INCIDENT CONTROLLER 2403 9922970217

Y R PATIL SPARES INCIDENT CONTROLLER 9881343527

G P NIRFARAKE PROJECTS INCIDENT CONTROLLER 2110/14 9881379299

A S PATIL PROJECTS INCIDENT CONTROLLER 9850816651

R B JAGTAP ASSEMBLY FIRST AID TEAM LEADER 9011567432

S G KHARADE PLANT ENGG FIRST AID TEAM LEADER

G P VARPE QA FIRE FIGHTING TEAM LEADER 2801 9822022580

P D MOKASHI QA EVACUATION TEAM LEADER 2801 9922424126



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9. EXTERNAL AGENCIES CONTACT DETAILS INVOVED DURING EMERGENCY

NAME OF THE ORGANISATION

RESPONSIBILITY ASSIGNED

CONTACT NUMBER

Statutory Authorities: Div. Commissioner Pune. Collectorate Office compound Police commissioner, Pune Police Control room Addl. Director, Industrial Safety & Health Pune Dy.Director, Industrial Safety & Health Pune.

Help during On site & Off site Emergency.

26361353 26122202 24266918 24268898

Police:

Saswad Police station 02115-222333

HOSPITALS: / DOCTORS: Chintamani Hospital Khade Hospital

Medical attention Surgical, burns cases Orthopedics, trauma case, Eye injuries Medical emergencies

02115-222037 9822327986 02115-222561

MUNCIPAL CORPORATION Local infrastructure Ambulance Services

02115-222349

Water Works

Supply of industrial

water

02115-222349

M S E B: Jr. Engg Saswad Pune Phursungi Power House

Electrical supply

02115-223196 020-26980270



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Fire Brigades Hadapsar Ind. Estate Pune Cantonment PMC- PCMC-

Fire fighting

02115-222349

MPCB, SRO- Pune-I Environmental troubles 020-25811029

10. INFORMATION ON THE PRELIMINARY HAZARD ANALYSIS

TYPE OF ACCIDENTS a. Fire b. Explosion c. Burn d. Significant aspect, hazard

SYSTEM ELEMENTS OR EVENTS THAT CAN LEAD TO A MAJOR

ACCIDENT

Storage & use of HSD, LDO Paint & Thinner storage & use Various types oil storage and handling Electrical transformer and distribution systems Storage & usage of gas cylinders

HAZARDS.

Sr. Areas Hazard / Risk

1. Paint and Thinner Storage Fire 3. HSD, LDO Storage Fire 4. Spray Paint Booths Fire 5. Compressor Testing Fire 6. Oil storage and handlings Fire 7 Electrical distribution systems Fire and burn injuries 8 Pneumatic testing of component Bursting of vessels Followed



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By explosion

This shows the major risk involved the fire hazards and subsequently losses to property damages and burn injuries to manpower, which resulted to major accidents and Emergency situation in factory premises.

SAFETY RELEVANT COMPONENTS.

SYSTEM ELEMENT SAFETY RELEVENT COMPONENTS

Paint booths,

a) Paint booth: - Flame proof electrical fitting. Effective ear things are provided to electrical distribution and equipments as well as paint booth. b) Down draft solvent vapor collection with water curtain absorption system is provided. c) Traces of solvent vapors along with water mist, generated during the tank water circulation of paint booth are blown above the work shed to disperse the vapors at elevated atmosphere. d) Situated at isolated location- by heat producing/creating activities. e) Maintaining inventory of flammable material at nearby area on day-to-day basis. f) Fire extinguishers are posted at strategic location.

Electrical transformer and distribution areas

Located at segregated places Transformer oil is checked annually for stipulated norms. Effective earthling grid is provided to distribution system and stimulated annually.



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Compressor testing areas

Relevant component of compressor are tested at stipulated pressure testing norms before assembling the compressor and followed during test performance. Isolated compressor test beds are provided.

ISD

Smoke and heat detection system is installed for early detection and followed by the warning actuating device.

Heat Treatment Furnace Due to Solvent leakage, fire Hazard may occur in the Shed

11. DETAILS ABOUT SITE

LOCATION OF DANGEROUS SUBSTANCES.

1. Paint and thinner storage area near main gate 2. Electrical transformers,. Dept. and ACR test bed area 3. Paint shops Location is shown in the attached Site master plan

SEAT OF KEY PERSONNEL

NAME LOCATION

Mr. D R Shinde ACR-MFG Machine Shop

Mr. A K Patil HRM Office

Mr. N M Bapat Safety Officer-M/C Shop

Mr. A S Chhapkhane Mfg-Office M/C Shop

12.EMERGENCY CONTROL ROOM (ECC). –



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During normal working hours – The (HRM) Office

During other times - The Security Office

Internal telephone no: 2001 External telephone no.: 02115-222409/403

For the purpose of handling emergency, the following Emergency Control

Centre has been identified.

All communications to and from will originate at this CONTROL CENTRE.

The Emergency Control Center will have the following: - Fire extinguishers layout and control points.

Layout duly marked with areas where large inventories of flammable

materials are stored.

General water supply layout.

Location of water storage for fire fighting purpose.

Sufficient stock of safety equipments and protective devices for use in

emergency.

Road map of entire plant.

Map indicating assembly points where people can be directed to gather

in case of emergencies.

Additional copies of general factory plans in which necessary areas can

be marked and given to the persons dealing with the disaster so that

they are clear about the location where they have to go.

List of persons who have done training courses in Safety Fire Fighting,

First Aid who could be called to the main control room in case of

emergency.

List of doctors, hospitals along with their phone nos.

Telephone nos. of fire brigades, blood bank, police control room, local

police stations and such other relevant information.

13. DESCRIPTION OF HAZARDOUS CHEMICALS AT THE PLANT SITE: DETAIL LIST IS ATTACHED AT THE END OF THE PLAN.

CHEMICALS (quantities & toxicological data)

Chemical Name Average storage quantity



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Paint &Thinners 2 KL

Various types of oils 3 KL

For toxicological data MSDS sheets are enclosed.

14. LIKELY DANGERS TO THE PLANT: - Disaster / Emergency may occur due to - (a) Company activities such as improper usage and storage of flammable

materials, lack of preventive maintenance, leakage from storage carriers, Fire in the vicinity, Mob Violence Riots, Food Poisoning, Plane Crash, Animal bites, Insect bites, Bombing etc. and

(b) Natural calamities as thunder, storm, earthquake, Flood, Lightening

etc. The action plan worked out for the disaster control is based on the above-mentioned causes.

In case of KPCL, due to factory activity, there is no probable risk to surrounding area of the factory as the manufacturing process is of General Engineering type and adequate provisions have been made for disaster control. Emergencies occur in any unit handling hazardous/flammable chemicals due to the LOSS OF CONTROL. Hence loss prevention is the only basic technique of avoiding such emergencies. These emergencies are classified as a. Fire b. Explosion c. Toxic release

The consequences are providing in the form of fatality of human being at different distances in case of various fires or explosions or toxic vapor release. The vapor cloud releases are hazardous to structures, glasses, and partial damages to human body & indicated in the form of eardrum rupture.

15. POTENTIAL HAZARD CASES CONSIDERED

a) Fire Hazards b) Bursting of vessels/receivers while testing of high-pressure

compressors followed by explosions. c) Electrical fires. d) Food Poisoning.

16. GENERAL GUIDELINES FOR EMPLOYEES

• Do not panic.



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• Do not approach the incident site as a spectator. Instead, stay at your place unless otherwise instructed in this manual for certain group of employees. Otherwise leave the place by bringing the operation at zero energy level and assemble at predetermined emergency assembly location.

• Do not engage communication channels / telephones except for handling the emergency.

• Do not move unnecessarily. • Pay proper attention to instructions received from the Task Force.

17.MEASURES TO BE EMPLOYED FOR MEETING THE OBJECTIVES:

• Define and assess the hazardous incidents.

• Provide the information to all concerned.

• Warning and advising affected people.

• Call-up for assistance from outside.

• Inform the employees, authorities and general public about the

assessed risks, safeguards provided, residual risk and the role to

be played by one and all in the incident.

• Collecting data on latest developments, other information and

requirements and disseminating the same.

• Coordinating action taken by various agencies.

18. HAZARD CONTROL MEASURES IN CASE OF EMERGENCIES

MANAGEMENT PLAN FOR HANDLING EMERGENCY

To deal with any emergency, the arrangement for immediate deployment or appointment of key personnel and their specific responsibilities must be well laid out. It may be noted that in an organization of KPCL, one or more tasks, referred to hereunder, may have to be performed by one person for effective and prompt action in case of an emergency.

KEY PERSONNEL

• It must be understood that the first few minutes after the start of an incident are most vital in prevention of escalation. Therefore, the



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personnel available at the complex on round the clock duty basis play the most important role. Some of them are the KEY PERSONS.

• The chart is illustrative and should be kept updated. It should be found at all times in the Emergency Control Center (ECC).

• It is to be appreciated that Key Persons remain the first line fighters. The

role of various coordinators is to assess the situation from time to time, take appropriate decision in consultation with the Chief Coordinator (Site Controller) and to provide timely resources.

• In case of an emergency, the two most important people are the SITE

CONTROLLER and the INCIDENT CONTROLLER. The Site Controller takes overall command and coordinates all activity within and outside while the Incident Controller takes charge of the incident site to tackle the emergency.

ORGANIZATION CHART FOR ON-SITE EMERGENCY MANAGEMENT.

SITE CONTROLLERS

INCIDENT CONTROLLER

COMMUNICATION COORDINATOR

TASK FORCE

NOTES:

• In case of the Incident, Controller being present on site, the standby personnel will report to him for directions.

• All the other employees will assemble at the emergency assembly points.



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19.EMERGENCY ACTION PLAN

ANY ONE NOTICING EMERGENCY SITUATION LIKE FIRE, EXPLOSION, TOXIC GAS LEAKAGE ETC. MUST DO’s

• 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.

DON’Ts

• Do not be panicky.

• Do not run – Walk fast.

INCIDENT CONTROLLER MUST

DO’s

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.

DON’TS • 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.



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• 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 organization

NOTE: 1) Messenger will wait until such time Security Officer arrives.

2) Also inform Telephone Operator.

SECURITY OFFICER / GUARD DO’s

• 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.

DON’Ts

• Do not entertain any outside call except for emergency purpose.

• Do not allow visitor to move around, from reception.

SECURITY GUARD

DO’s

• 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.



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• Render all possible help for controlling overall situation.

DON’Ts

• Do not leave the site unless asked to do so.

EMERGENCY VEHICLE DRIVER DO’s

• 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 Driver’s seat of the vehicle.

• Take the injured to the hospital as directed.

DON’Ts

• Do not leave the vehicle.

• Do not take the vehicle very near to the site.

INCIDENT CONTROLLER

DO’s

• 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 DO’s • Will approach emergency site immediately / Assess the situation.



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• 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.

DON’Ts • Do not instruct to blow ALL CLEAR siren unless the situation is fully under control.

• Don’t evacuate the entire plant unless the situation demands.

FIRE FIGHTING SQUAD ON HEARING SIREN DO’s

• Inform fellow employees/Officers.

• Report to Fire Squad Assembly point.

• 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.

DON’Ts • Do not leave process/equipment in UNSAFE CONDITION.

• Do not leave emergency site unless ALL CLEAR siren blown.

• Do not use improper fire extinguisher.

• Do not be panicky.

RESCUE SQUAD DO’s

• 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.



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• 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 DO’s

• 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.

• Help in taking roll call.

• After hearing ALL CLEAR, go back to the departments.

• Start the work again after setting instruction from Incident controller.

DON’Ts • 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 AND HEALTH DEPARTMENT ON HEARING SIREN DO’s

• Be available in Engineering Department at respective location for any help.

• Approach emergency site with required tools and equipments and should work on

instructions of Incident controller.

• 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 stopgap arrangements as per the requirement of Incident Controller.

• Carry out electrical isolation of area as per instructions from Incident Controller.



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ADVISORY COMMITTEE (ALL DEPARTMENT HEADS) DO’s

• Approach emergency site as early as possible.

• Render advise to Main Incident Controller and Main Site Controller to control

emergency.

COMMUNICATION COMMITTEE – (P&A) DO’s

• 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.

DON’Ts • Do not communicate to any one or brief press without permission of Main Site

Controller.

GENERAL INTRUCTIONS DO’S

• 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.

DON’Ts • 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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20.IDENTIFIED EMERGENCY & ACTION PLAN

Some time due to individuals’ carelessness, accidents take place. These types of accidents may lead to a major incident. Some of the Potential Accidents & The actions taken during this period are given below: -

In case of Electrical Short circuit due to unauthorized Operation: -

INDIVIDUAL WORKER ON THE SPOT:

Remove injured persons from the spot to First Aid Centre. First Aid is an immediate and temporary care, given to the victim of an accident or sudden illness.

First aid is to preserve life, assist recovery, prevent aggravation and minimize complication at later date and minimize pain / agony

Ask near by co-worker to inform the matter to SUPERVISOR. Inform the maintenance department to take further necessary action.

Remove the patients from the source of danger. Make the air passage clear and clean. Restore natural breathing by artificial respiration. Send the patient to the hospital.

In case of Snakebite due to unauthorized movement at boundary: -

Act quickly. Do not allow the person to run. Apply a ligature above to the wound (In between the heart and wound) if the bite is in the leg or hand. Wash the wound with Potassium permanganate solution or with soap or water.. Reassure the patient and immediately hospitalize.

In case of Burns and Injury: -

* Place the part under running cold water.

* Cover the wound with several layers of sterilized cloth

* Artificial respiration if needed

* Prevent or treat shock

* Immediate medical attention

Inhaling of fumes / Chemical burns on the eyes: - Immediate washing of the Eyes at least for fifteen minutes. Apply sterile bandage and send the patient to the hospital.

Suffocation: -

Remove the patient from the source. Restore respiration by artificial respiration. Send the patient to the hospital if necessary.

Unconsciousness: -



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Make the patient lie down in prone position. Check breathing, pulse & heartbeat. Loosen tight clothing. Clean the airway. Give artificial respiration. Give external cardiac massage. Transport the patient to the hospital.

SHIFT INCHARGE /SUPERVISIOR

Rush to the spot

See the injured person are moved to first aid centre and if required moved to

hospital.

Organize ambulance/ Transport available and additional work force to move the

individual to hospital.

See there is no unwanted worker near the accident site/move all to a safe

assembly area.

Inform the matter to HR/P&A and Plant Head

Inform the security guards who are the coordinators.

Study the root cause of the accident.

Carryout detailed root cause analysis.

Submit the report to Plant Head.

CO-ORDINATOR: Security guards / Rescue team of the Factory will be performing the duties of

coordinator on hearing the accident and will ensure the following: -

Rush to the accident site.

Evacuate the injured persons to first aid centre and further to hospital.

See no unwanted persons are around that area.

Prepare the detailed report on damage, salvage, injuries, hospitalized and cause

of incident/ initiate root cause analysis.

See necessary corrective actions are taken and implemented.

EMERGENCY IN HEAT TREATMENT PLANT Due to Solvent leakage, fire Hazard may occur in the Shed,

Precautionary Measures installed:

Solvent vapor detection system installed at four station

Incase of any leakage



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THE WORKER ON THE SPOT:

If there is any type of Leakage of Gas, it will be immediately detected by the system, in that case the Siren will get activated and on the display screen will show the location of the leakage, the operator should immediately stop the valve and or collect the solvent in safe container.

If the leakage is beyond manual control, in such case to avoid further danger, the present operator must close the valve of concern Gas carburizing service tank, and also necessary precaution to avoid scattering of chemical spillage.

Whenever such incidence occurs, immediately the gas cutting and welding operation should be stop, as well as electrical equipment should not be turned on or off which may result in spark or vapor can catch fire.

Whenever such occurrence happens all chemicals in stored in service tanks should be collected through safe method and must be stored in another safe place and fire extinguisher should be brought near Gas carburizing process unit, which will be used only incase of fire hazard.

Jet water should be sprayed on the affected area, which will dissolve the chemical in the water and danger of fire will be eliminated.

It should be ensured that dust should not be accumulated in the service tank cabinet it should be kept dust free.

And ensure while cleaning the cabinet water on floor or any other object should come into the contact of the Gas detection unit for which provided cap should be used.

SECURITY GUARDS:

See the plant is put off.

See required additional labors are mustered and provided to the contractor.

Provide necessary materials like sand bag, fire extinguishers and sands.

See no worker is near by the plant and all persons not required are removed from that area.

Inform the matter to coordinator SHIFT INCHARGE /SUPERVISOR, HR, Site Controller.

Over see the removal of all the waste properly as there are hazardous materials.

Study the root cause for the failure of the plant.

Recommend the course of action to be taken so that such incident does not take place in future.

COORDINATOR/TEAM LEADER: The Site Controller will be the coordinator for these type of incident:-

On hearing rush to the spot. See the plant is put off.



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See necessary safety equipments are provided to the labors (Like face mask, hand gloves, gum boot etc)

See no unwanted persons entered that area. See required fire extinguisher/ sand available to pour over the fire. Make sure these items are removed and disposed off as per laid down

procedure. Study the root cause for the failure of plant with premises engineer. Prepare a detailed report on the failure salvage disposal and root cause analysis. Recommend a proper remedial action for this and see that the recommended

action is implemented. Inform the Site Controller the action taken and disposal of the hazardous

materials.

SUDDEN SPURT OF LEAKAGE HAZARDOUS MATERIAL/ OIL

Due to failure of old pipes line oil/steam may suddenly spurt off from the line or machine. The actions taken during these emergencies are: WORKER ON THE SPOT: On seeing the oil leakage the worker should do the

following:

Immediately shut off the machine. Stop the flow of oil to the machine/pipe line by closing it at the main. Shut off the power supply to the area. Inform the matter to Supervisor. Try to put sand /saw dust over the oil spilled over. Remove other materials from that area. Remove other workers from that area.

SUPERVISOR /INCHARGE

On seeing / hearing rush to the spot. See all machine are put off. See the oil line is shut off. Power supply to the area is put off. Inform the incident to HR/P&A. Ask Security guards to provide additional labour to remove the spilled oil from the

area. See other unwanted materials are removed from that place.

See no other unwanted persons are there. Study the root cause for this incident. Carryout the detailed analysis of the problem.

The Rescue team



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Rush to the spot

See the oil supply is cut off.

See the power supply is put off.

See no UN -wanted materials are there, if so remove them from that area.

See the workers are provided with proper safety kits like gloves, mask etc.

Muster additional work force to remove the spilled oil.

See the salvaged items are disposed off as per mitigate procedures.

Investigate the root cause of the incident in detail.

Submit a detailed report to the Plant Head

Recommend corrective actions.

Ensure remedial actions are taken and implemented accordingly.

All hazardous materials are disposed off as per mitigate procedure. IDENTIFICATION OF THE INCIDENCE: - MASS FOOD POISONING

Persons approaching with symptoms of Vomiting, Nausea, Fainting, and Stomach ache, Loose Motion etc. after consumption of Food prepared in the Company canteen.

Arrange for immediate Medical assistance to the persons approaching the OHC.

The company Doctor will assess the situation and accordingly take the required action. Whether to provide internal Medical relief or arrange for external medical assistance.

IDENTIFICATION OF AFFECTED AREA: -

To find out in which lunch break the affected persons consumed food.

Immediately stop canteen serving.

Try to Investigate with the affected persons, which they consumed Items in the canteen.

Identify the common food consumed by the affected persons.

Seal the Food prepared.

Location wise Identify through the rescue team the whereabouts of the

Persons who were scheduled in the same shift and consumed food



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prepared in the canteen. Assemble them at the Ganesh Hall and examine for Food Poisoning symptoms and its severity.

Immediately liaison with nearby hospital and arrange for accommodation

of affected persons for facilitating Medical relief.

Monitor the health symptoms of the affected persons.

The rescue team will be assisting OHC in the relief activity. 21. EMERGENCY PERSONNEL'S RESPONSIBILITY DURING DAY SHIFT

1. Site Controller:

. Responsibilities:

The Site Controller will assume the overall responsibility for the factory site and its personnel. His duties are to:

Assess the magnitude of the situation and decide if staff needs to be

evacuated from their assembly points to identified safer place,

Exercise direct operational control over areas other than those

affected,

Undertake a continuous review of possible developments and assess

in consultation with Key Personnel as to whether shutting down of the

plant operations or evacuation of personnel if required,

Liaise with senior Police, Fire brigade, Medical officers and Factory

Inspectorate and provide advice on possible effects on areas outside

the factory premises,

Look after the rehabilitation of affected persons after discontinuation of

emergency,

Issue authorised statements to news media and ensure the evidence is

preserved for inquiries to be conducted by statutory authorities.

Permit resumption of normal operations only after post emergency

clean up.

2 Incident Controllers: Responsibilities:



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Immediately, on knowing about the emergency, he will rush to the incident

site and take overall charge and report to the Site Controller. On arrival,

he will assess the extent of emergency and decide if major emergency

exists and inform the Communication Officer accordingly. His duties will

be to:

Direct all operations to stop within the affected area taking into

consideration priorities for safety of personnel, minimise damage to the

plant, property, environment and minimise loss of materials,

Provide advice and information to the Fire fighting team and Security

staff and to the local Fire Service,

Ensure that all non-essential workers / staff of the areas affected are

evacuated to the appropriate assembly points (gate) and the areas are

searched for casualties,

Set up communication point and establish contact with Emergency

Control Center (ECC),

Report on all significant development to the communication officer.

Have regard to the need to preserve the evidence so as to facilitate

any enquiry into the causes and circumstances of the incident.

Assess damage and plan for post emergency clean up before advising

Site Controller to resume normal operations.

3. External Coordinator: Human Resource Manager Designated Person: Mr. A K Patil

Responsibilities: The External Coordinator will also work as a liaison man and will be

stationed at the main gate. He will, under the directions of the Site

Controller, handle Police, Press and other enquiries.

His responsibilities shall be:

Liaison with external agencies and call fire brigade aqua

To ensure that casualties receive adequate attention / to arrange

additional help if required and inform relatives.



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To control traffic movements into the factory and ensure alternative

transport is available when required.

When emergency is prolonged, arrange for relief of personnel and

organize refreshments / catering facilities.

4 Communication Coordinator: Designated Person: 1. Mr. G P Nirfarake

(In order of availability) 2. Mr. Yoovraj Patil

Responsibilities: On hearing the alarm, he will proceed to the Control Room and maintain

communication with the Incident Controller. He will:

Advise the Site Controller of the situation, recommend evacuation of

staff from assembly point,

Recruit suitable staff as runners between the Incident Controller and

himself,

Maintain prior agreed inventory in the control room,

Any other work as per directions of Site Controller or Incident

Controller.

5 Sr. Security Officer: Designated Person: 1. Mr. P R Kadam

(In order of availability) 2. Mr. K A Mhaske

The main in-charge of this function will be responsible for fire fighting. On

hearing the alarm , he shall reach the site and get directed by the Incident

Controller to fight the fire.

He shall be responsible for organizing the fire fighting team; ensuring that

the personnel are using correct personal protective equipment and he

shall direct the resources so as to put them to optimum utility.

Fire fighters: The list is attached at the end First Aiders: The list of trained first Aiders is attached at the end Evacuation/Rescuer: Security Personnel present at the site.

6 Other Personnel: Telephone Operator on duty:



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After receiving the information/emergency given, he will immediately contact

the Site Controller and work as per Site Controller’s advice and call the local

fire brigade or mutual aid scheme members, if require.

He will ensure that all internal communication lines are available for dealing

with the disaster. He will give direct communication to telephone lines in

control room. He will keep the list of important telephone numbers such as

fire brigades, ambulance services, hospitals etc.

7 Operation Manager (Utility & Services) : After getting the information or knowing about the emergency situation, he

will report to Incident Controller and provide assistance as required. He will

decide which member of their staff / workers require at the Site. He will

ensure that adequate water supply is made available at the Site He will

arrange for electrical shut down from main receiving station. These people

should report to Incident Controller for directions.

8. Other department 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. The Various department head on hearing the Emergency should take charge

and facilitate evacuation of his respective department towards the nearest

Assembly point and should he rush to the assembly point.

9.First-aid Team Members: 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 daytime. 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 doctor’s room and request the



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Incident Controller to inform the destination (hospital, etc.) advising them about the

casualties reaching there.

10. 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.

22.EMERGENCY PERSONNEL'S RESPONSIBILITIES DURING NIGHT SHIFTS AND HOLIDAYS. Security Officer / Supervisor:

As soon as he becomes aware of the emergency and its location, he will

proceed to the scene. On arrival, he shall assess the scale of the incident and

direct the operations for containment or extinguishment with the following

priorities:

Secure the safety of persons. This may require evacuation to the assembly

points (gate). In the event of escape of material if the wind direction is

adverse, choose appropriate assembly point,

Try to minimize damage to plant, property and the environment,



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Have regard to the need for preserving evidence that may facilitate enquiry

later on.

Arrange to inform Site Controller, Incident Controller. Also call for other

personnel till Site Controller / Incident Controller arrives.

Act as Incident Controller till his arrival.

Advise local Police/Fire stations/Mutual aid members as deemed necessary.

23. COMMUNICATION FACILITIES The success of any emergency management preparedness/plan will depend

entirely on how well and how timely was the communication. More effective the

communication system better will be the outcome and more effective

implementation of the emergency management plan. It is vital for gathering

information, for overall coordination and for passing timely information. Company

is having all communication facilities so that messages can be sent immediately

such as internal telephones, external telephones, E-mails, Mobile phones to Key persons, walkie-talkie set etc.

24. DETAILS OF OTHER SERVICES AVAILABLE ONSITE OCCUPATIONAL HEALTH CENTER

KPCL-Saswad has Occupational health center (OHC) necessary material and equipment to handle emergencies. It has following features.

• Well-equipped department with qualified and experienced staff.

• First aid services are available on all working days.

• There is well-equipped ambulance with the driver available round the clock

for shifting any emergency case.



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• It has full range of routine as well as emergency medicines available for the

treatment of injuries. The doctor issues a pack of medicines for continued

treatment proportional to the nature of injury/accident.

• Emergency first-aid box duly equipped are available to deal with on-site

cases in case emergency arises. All the shops are equipped with first aid

boxes with necessary first aid material. The material is replenished as and

when required through OHC.

• The OHC is equipped with necessary resuscitation equipment like -- There

are two observation beds available for short-term follow-up of the patients.

• The Management has recognized few hospitals near / around area for further

treatment of surgical, medical, orthopedic, hand surgery emergencies.

• The doctor and social welfare counselors maintain a liaison and follow up with these hospitals telephonically and by hospital visits.

EMERGENCY POWER DG set is installed available to ensure emergency power supply to critical areas, if normal electricity fails.

WATER SOURCE There is abandoned water storage capacity in the available tanks.

THE EMERGENCY TELEPHONE NUMBERS The emergency telephone nos. are provided to all departments and displayed in key locations.

25. METHOD OF REPORTING EMERGENCY SEQUENTIAL ACTIONS DURING EMERGENCY

Incident There are possibilities of occurrences of various types of the accidents or mishaps in the factory premises or around the factory. Most of the occurrences will be of minor nature. While few occurrences may be of major type. If the factory is fortunate enough, there may not be a single incident or mishap during its lifespan. However, when any incident occurs, it cannot be distinguished immediately whether it is minor or major, the subsequent development, or gravity of situation or seriousness of such occurrence is required safe handling irrespective of its nature, if it cannot be controlled.



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It should be general practice that whenever any person notices the accident/ fire/ explosion/ mishap at the site, he should immediately shout “FIRE”, “FIRE” or “HELP” , “HELP” and such message should reach to the Supervisor/ Shift Officer/ Senior Person of the unit.

Responding Actions It is needless to mention that the root cause of occurrence should be removed immediately. Similarly, if any incident takes place in the premises, using available resources, within the factory as well as nearby, to their optimum, it should be so responded that the incident is contained immediately before spreading. If the incident looks severe and could not be controlled by simple efforts, the Shift Officer or Senior Personnel should rush to the place and make every effort to control the incident using various resources at the site. Further, if the incident is uncontrollable even using own resources, he should immediately call for additional helps form outside resources such as Mutual Aiders, Fire Brigade, etc. He should act the incident Controller and immediately start the following actions.

Sound the siren or ring the emergency bell.

Take continuous responding actions with the use of other helps.

Call the higher authorities and Site Main Controller. While conveying the messages regarding the incident, the following details should be incorporated.

• Brief description of incident • Type of help required & direction

• Chemical involved & Quantity

• Action immediately taken

• Development of the incident

The person who first detects any type of hazard or emergency will report to emergency control centre (Time Office) through available communication channel. Personnel at ECC will receive the first hand information and he should immediately pass on the same to the Incident controller. Depending upon the gravity the ECC will actuate the Emergency Siren



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(a) Incident Controller will give the information about the Incident in brief to Site

Controller.

(b) Try to control the emergency, leakages by available means.

On receiving the information of the Incident controller Rescue crew (Task Force)

should rush to the Incident Site with fire extinguishers / mobile water tanker and

assess the magnitude of situation and try control the situation. Time office is the

main emergency control center for disaster control and has been marked on the

plan. The control room acts as focal point in case of an emergency from where the

operations to handle the emergency are directed and co-coordinated. It is equipped

with Site plan; external and internal telephone numbers and connections, hospital

telephone numbers etc. The public address system such as loudspeaker, list of

essential telephone numbers, list of key persons and their addresses, a list of

chemical and hazardous substances and their safety data sheets.

TASK FORCE: The trained fire squad members are available for handling the emergency situation in the factory shift-wise. The task force will consist of the following: (a) Trained fire squad members.

(b) Elect. and Maintenance. Staff Workers on duty.

(c) Security guards.

Duties of Task Force: a) Fire Fighting

b) Emergency engineering work i.e. isolating equipment and process materials.

c) Movement of equipments to or from the scene of the Incident.

d) Provision of first aid.

e) Acting as runners, manning assembly points and communication centers

26.EMERGENCY ASSEMBLY POINTS: In case of emergency, upon hearing the warning alarm employees of the

company, contractors, and visitors will assemble at the nearest Assembly point.

The designated assembly point observer will take the roll call and communicate it

with Site controller.



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A list updated for employees department-wise shift-wise is made available so

that roll call could be taken.

LOCATION OF EMERGENCY ASSEMBLY POINTS: - 1. Near Ganapati Mandir 2. Near HRM & Admin office

ALL ASSEMBLY POINTS ARE MARKED WITH YELLOW COLOR IDENTIFICATION BOARD. (The site Map attached shows the location)

27. EMERGENCY ACTIONS

On receiving information, the Emergency Control Centre will activate and

urgently establish the contact with the required persons, agencies and authorities.

The essential workers, responsible to carry out certain specific functions, will

have to start work immediately. Plant engineering, civil dept, Security.

The non-essential workers should go to the assembly center. The Roll Call should be started.

The cordoning the incident area will be ensured. (By Task Force) The water should be sprayed on the flammable storage tank, even if not caught

under fire. (By Task force)

The experts for the responding to emergency situation will be consulted, if required.

The authorized officer will provide authentic information for incident to Press/

Public only.(External Co-Coordinator)

Removal of the flammable, dangerous materials, cylinders, etc. will be arranged along with isolation from fire.

The trapped personnel, if any, in incident will be rescued (By Task Force)

All assistant will be provided to the Fire Brigade to control spreading of fire.

Any remotest possibility of re-ignition or explosion will be looked into and

controlled. 28. SHUT DOWN PROCEDURE:

The Plant Engg department personnel present on the site, on hearing the Emergency siren will instantly establish contact with the Site controller:-



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They will gather the information on where the Mishap or emergency has

occurred, the nature and extent of damage accordingly: The Main electrical supply will be cut-off/ switch-off. Similarly, the pipelines

supplying flammable gas, liquid or chemicals will be immediately shut –off by valves and will be isolated from the process line.

The rescue team members shall assist the Plant Engg personnel. After mitigation they will analyze the situation and as per instructions of Site

controller will arrange for re-start of the plant or the section. This process shall be known and communicated to Maintenance and plant Engg Head.

29. POST EMERGENCY The internal committee will be formed to investigate into the causes of the accident/ incident comprising Key persons listed above they will ensure the all below points: - Once the emergency situation will be bought under control, following post emergency actions will have to be taken.

The affected area will be declared safe from any toxic and other after effects by

Maharashtra Pollution Control Board authority after through checking and confirmation.

Then the Government authority will declare the emergency as over and

rehabilitation work will be started in the area.

Then emergency clear siren will be blown.

The rehabilitation work will be started in the affected area. It will be ensured that all fires are extinguished and there is no risk of re-ignition prior to commencement of rehabilitation.

It will be ensured that there is no chance of secondary explosion.

The wreckage and debris at incident site will not be disturbed, expect for

rescuing the injured personnel or for recovering the dead bodies, until permitted to do so by the statutory Authority.

All victims, dead or alive, will be systematically identified and the records will be

kept accordingly. If asked for, necessary information may be provided to the victim’s relatives.

All relevant information will be recorded.

Photographs/video of incident site will be taken or suitable sketches of the

incidence will be prepared.



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The incident will be reported to the statutory Authorities with complete details of occurrence/ accident, if not informed.

Necessary permission for restarting the plant will be obtained from the statutory

Authorities.

The registers for recording the incident, relevant entries, details, inventory, list of persons, etc. will be maintained and all the relevant documents, log books, maps, registers and all records taken from the site will be preserved.

The record of help, Co-operation etc. from Mutual Aiders and sought from others

will be maintained and letters of gratitude will be initiated to all of them.

Details of expenses incurred during the emergency will be worked out and allocated to different heads and the records will be maintained. Statement for total expenditures will be prepared.

All necessary cooperation will be extended and help will be provided to the

Agencies, Authorities, who will be enquiring into the incident.

The internal committee will be formed to investigate into the causes of the accident/ incident, if necessary.

30. CORRECTIVE ACTIONS

The accident is always eye- opener toward the irregularities. Similarly, the

occurrence of major emergency directly indicates the shortcomings or weakness of the plant, handling method, transportation, working procedure, storage procedure, unsafe condition or unsafe actions, etc. It may reveal from the investigation or recommendations of the committee.

Necessary corrective steps/ actions in light of the investigation report or findings

are required to be taken to ensure that such emergency accidents do not repeat. Therefore, modification, alterations, changes in operation, instruction, process, handling, etc. as suggested by investigating Authority and internal committee should be implemented accordingly to make the plant working

31. REHEARSAL / SIMULATION /MOCK DRILL

Exercise / Rehearsal / Simulation for working of ON- SITE- EMERGENCY PLAN are known as MOCK DRILL. As a normal practice, it is recommended to conduct the Mock Drill at an interval of around 6 months, or after modification of hazardous process, storage, plant operation, and extension. OBJECTIVE



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It is necessary that all aspect of emergency plan are tested sufficiently often to ensure that the personnel and equipment involved in emergency plan carry out their responsibility and function as specified and particular to:

Test the response from workers, emergency services, and other responsible

persons. Test and evaluate the interaction of various agencies / authorities involved and

ensure that all components are properly coordinated.

Evaluate the available resources, equipment, their effectiveness, accuracy

Gain more and more experience.

AUTHORITY OF EXERCISE / REHEARSAL

The site controller of the Company is required to assume the responsibilities to make decision be seen as legitimate. Table Discussion The first part of experience is ‘Table Top’ exercise to test emergency plan may not in any way interrupt the day-to-day running of their respective concerns. This exercise will recognize the difficulties involved and practical approaches to encounter the same. The scenarios will be decided and consideration will be given to live practices involving all concerned at suitable intervals, in addition to those of a theoretical nature. NATURE Origin, date and time, location and duration of Mock Drill exercise etc. will be pre- decided in particular manner. AFFECTED AREA It is the indication of the spread of disaster. This will be reflected in Blue print, given detailed of original place, units, surrounding identities etc. PREPARATION STAGE The responsibilities & duties will be allotted to each group, services, etc. involving all personnel. Educative meeting will be arranged and the role of each participant group will be explained in detail. SEQUENTIAL ACTIONS The whole exercise / rehearsal will be arranged in the form of sequential actions, to be taken one by one, as per Onsite Emergency Action Plan. Thus, actual exercise will be conducted, as rehearsal. OBSERVATIONS



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The outside / third party will perform the role of observers and they will submit their reports on various site- observations with shortcomings and good features. DE- BRIEF MEETING On completion of exercise, a de-briefing meeting will be convened to discuss the features of conducted exercise; to give views on performance of each area; explain difficulties; resources; limitation; planning; etc. All these observations along with corrective steps will be noted and the reports will be prepared circulated to concerned and maintained.

List of Fire Fighting team (Rescue Team) for Saswad plant MEMBER OF TASK FORCE

1 ACR Administration S.B.Nair 2 Saswad ACR Projects shed Ganesh Nirfarake

3 Jagdish Zha



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4 P T Kurhade 5 V B Dusang 6 S A Mahajan 7 Swapnil Gawad 8 P C Bodke 9 Machine shop S S Khaladkar

10 G M Lawande 11 N N Raut 12 Fabrication Shop I K Sayyad 13 Assembly shop S V Vaidya 14 Dispatch / Paint shop A S Mane 15 N D Rithe 17 N S Wangikar 18 Plant Engg S S Kadbane 19 S G Kharade 20 Spares / Stores Maruti Amane 21 Materials Dept. V S Raut 22 Security P R Kadam 23 K A Mhaske 24 S T Memane 25 V M Chandgude 26 R N Pawar 27 Casuals S B Mhetre 28 Canteen V K Gupta

First aid Trained Employees & Contractors for Hadapsar & Saswad plant MEMBERS OF TASK FORCE

Sr.No. Div Department First aid Nomination T.No.

Contractors Name (If appli)

1 ACD ACD Machine shop P B Pathare 10181



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2 Plant Engg. ACD V V Kikle 8355 3 ACD BOP Assembly P R Khamkar 10440 4 ACD EH/RBC Assembly G S Dixit 4622 5 Dispatch T S Kawade 7060 6 GSU+ Centrifugal Assly T B Kamble 9032

7 Shot blasting / Pattern shop N K Gaikwad

8 Foundry S R Memane Hardseles Engg

9 TRM New TRM Shed S Perodiya 10404 10 Heat treatment V P Jagtap 10135 11 P G Sawant 10397 12 TRM CNC/ Machine shop A A Salunkhe 10052 13 S S Chougule 10458 14 Plant Engg. TRM A.R.Thosar 10181

15 CORPORATE Administration Building S P Bhalke Eagle Services

16 COMMAN R & D Building R V Nigade 10299 17 Materials Bldg D S Sonar 10114 18 ACR / IT Building L T Pande 8163 20 Canteen R R Hirve 10544

22 Security Hadapsar R M Ghodake Security Officer

23 B A Kale Eagle Securities

24 OHC S S Kapare Shamrao & Sons

25 ACR (SASWAD) Machine shop Santosh Patil 10569 26 Assembly shop L D Kirdat 7017 27 ACR Projects Jagdish Zha 10593 28 Stores / IT / Materials S S Jagtap 8759 29 Security Saswad P R Kadam 10623



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LIST OF AMBULANCE DRIVERS HADAPSAR & SASWAD

Sno Name Of security Personnel Cell Number

First Aid Fire fighting

1 JSO R M Ghodake 9922959694 Yes YES 2 Dighe R B 9767413724 Yes YES 3 Jadhav N D 9604602214 Yes YES 4 Pisal D S 9822964889 Yes YES 5 Sanjay P Bhosale (Saswad) 9881469413 YES 6 Sharad P Bhosale (Saswad) 9766874542 YES

HADAPSAR EMPLOYEES TRAINED ON FIRE FIGHTING IN AUGUST 2010 Sno Name Dept

1 S D PATIL HEAT TREATMENT 2 R J RANAWARE ACD ASSEMBLY 3 M S GAWALI ACD ASSEMBLY 4 N V TIKHE PLANT ENGG 5 D B TAMBE ACD ASSEMBLY 6 B P DIXIT ACD ASSEMBLY 7 V W KANASE HEAT TREATMENT 8 D D MANE ACD ASSEMBLY 9 K R MHETRE PLANT ENGG

10 A K SHINDE CORP-QA 11 M E GAIKWAD IT 12 D R JAGDALE ACD-MACHINE SHOP 13 VINOD BANSODE HRD 14 D S RATHOD SECURITY GUARD 15 S P SURYAWANSHI SECURITY GUARD 16 A S KALE HRM 17 S T JADHAV TRM M/C SHOP 18 K R JAGTAP TRM M/C SHOP 19 JADHAV S R TRM M/C SHOP 20 S V KUMBHAR TRM M/C SHOP 21 B S LIKHANDE PAINT SHOP 22 T S KAVADE DESPATCH 23 M Y KULKARNI CIVIL 24 R S MEMANE FOUNDRY 25 S M AGARKAR STORES 26 YOGESH SARAF IT



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SASWAD EMPLOYEES TRAINED ON FIRE FIGHTING IN AUGUST 2010

1 ANAND KULKARNI PROCUREMENT 2 A S MANE MFG ENGG 3 D G GUMASTE ACR-ASSEMBLY 4 PRADEEP DEV ACR-PROJECTS 5 JAGDEESH HARLAPUR ACR-PROJECTS 6 M D KAMBLE ACR-PROJECTS 7 S A MAHAJAN ACR-PROJECTS 8 S G PHATANGARE ACR-PROJECTS 9 GANESH NIRFARAKE ACR-PROJECTS

10 P B PATIL ACR-ASSEMBLY 11 G M LAWANDE ACR-M/C SHOP 12 N N RAUT ACR-M/C SHOP 13 B V MANE ACR-M/C SHOP 14 V G KENGAR FABRICATION 15 P W THAKARE QA 16 UMESH JADHAV YASH ENGG 17 S A KALASKAR 18 V B DUSANG QA 19 B V KUMBHARKAR SECURITY GUARD 20 PRAKASH KADAM SECURITY OFFICER 21 M R GUPTA 22 N G BADHE 23 I K SAYYED FABRICATION



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EMERGENCY ORGANIZATION CHART

Fire fighting Squad

First aid Squad

H R M Dept

Utility Manager

Production Heads

Security Dept.

Safety Off

Shift In charge

Site controller

Incident Controller

Documents

Onsite Emergency Preparedness Plan Saswad Final