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CHAPTER 7.0: RISK ASSESSMENT AND DISASTER
MANAGEMENT
7.1 Introduction
M/s.Nakoda Chemicals Limited proposed to expand the production
capacity of existing Bulk Drugs and Bulk Drug Intermediates
manufacturing plant at Plot No. 64/A and 65/B, Phase-I, IDA
Jeedimetla, Medchal District, Telangana State. The site is situated
between 17030’59.8” North and 17031’03.3 North Latitude and
78027’04.7” East and 78027’07.8” East Longitude. The existing land
area of the plant is 1.25 acres. The unit acquired additional land of
2.74 acres adjacent to the site in Plot no. 65/B for expansion
activity. Thus the total area of the unit is 4.0 Acres.
7.2 Site Location and Surrounding
7.2.1 Site Location and facilities
M/s. Nakoda Chemicals Limited, IDA Jeedimetla is Surrounded by
Road on all sides and Neo spark chemicals on the Eastern side.
Following facilities are there in the unit
• Production Area
• Ware House
• QC/QA laboratory
• Utilities Block
• Services area
• Generator Room
• Effluent Treatment Plant
• Cooling towers
• Purified Water system
• Scrap yard
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7.2.2 Description of the area around the installation:
East : Neo Spark Chemicals
South , North & West : Road
Table 7.1
Surrounding features of the site with distances
Area Distance Remarks
Resident/Village area 0.7 km Shapur nagar
Market 0.7 km Shapur nagar
Govt. Hospital 0.8 km Gajula Ramaram road
School 0.7 km Primary & Secondary
Others:
Railway Station
Police Station
7.0 km
0.8 km
7.3 Objectives and Scope
The production of synthetic organic chemicals involves usage of
many chemicals which are both hazardous and non-hazardous in
nature. Risk analysis has been carried out to identify the hazardous
materials and quantify the hazards to arrive at safe disaster
management plan and emergency preparedness plan for storage
and handling of the potentiality hazardous materials. Also the
purpose of carrying out risk assessment study for M/s. Nakoda
Chemicals limited is to obtain clearance from the Ministry of
Environment and forests (MOEF) which calls for a study on nature
of hazards due to proposed location of process and storage units
and also to study whether any accident, if occurs leads to any off-
site disaster. In this endeavour, the study objectives are outlined
here under.
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i) Hazard identification and Visualization of Maximum
Credible Accident Scenarios.
• To identify major hazards relating to fire, explosion and
toxicity due to chemicals, processes and storages of the
proposed units.
ii) Hazard Analysis and Risk Assessment
• Hazard analysis is the process of determining the release
probabilities and quantities, emission or release rates, the
routes/pathways by which the released substances could reach
the receptors, the fate of the substances in environmental media
through which they are transported or moved and the
characteristics of the receptors at risk.
• Disaster Management To provide guidelines for Disaster
Management Plan(DMP) for on-site emergencies and Emergency
Preparedness Plan(EPP) for off-site emergency, based on above
i) & ii) studies of proposed plant.
7.4 Production Details
The manufacturing capacities of are presented in Table 7.2
Table 7.2
Manufacturing Capacity of Proposed Products
S.No Product Name
Production Capacity
TPM
Product Description Drug/Intermediate/
Multipurpose
chemicals
1 Norfloxacin 2.08 Drug
2 PefloxacinMesilate di
hydrate 0.83
Drug
3 Acetazolamide 6.67 Drug
4 Lomefloxacin HCl 0.33 Drug
5 Famotidine 2.50 Drug
6 Ecabet Sodium 5.00 Drug
7 Menatetrenone 0.08 Drug
8 Prolonium Iodide 0.02 Drug
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9 Stearic Hydrazide 0.02 Drug
10 Azelastin-1 0.02 Drug Intermediate
11 2 (2-Methoxy Phenoxy)
ethylamine (Anisole) 0.83 Drug Intermediate
12 n-Benzyl-n-ethyl-3-acetanilide 0.08 Multipurpose Chemicals
13 n-(3-ethyl(phenyl
methyl)) butyranilide 0.50 Multipurpose Chemicals
14 1,2,3,9-tetrahydro-4 H-
carbazol-4-one 0.19 Drug Intermediate
Total 19.17
Bi-Products
1 Weak Piperazine 42.15
2 n- methyl piperazine ML 10.7
3 Gum Residue 10.1
4 Weak acid (Acetic) 40.6
5 Dil Formic acid 0.2
6 Mixed Ammonium Salts* 54.2
* Mixed Ammonium salts are generated whenever Stage I and III
Effluents of Acetozolamide are treated in house
7.4.1 Process Description
The details of process are given in Enclosure I of Chapter 3
7.5 Hazard Analysis and Risk Assessment
7.5.1 Introduction
Hazard analysis is the process of determining the release
probabilities and quantities, emission or release rates, the
routes/pathways by which the released substances could reach the
receptors, the fate of the substances in environmental media
through which they are transported or moved and characteristics of
the receptors at risk. The basis of risk estimation is to determine
the dose-effect relationship between an indicator chemical and
receptor. Estimation of risk follows only when the hazard analysis
shows a frequency or occurrence, which is significant.
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Risk evaluation is the process of identifying, whether the estimated
level of risk is tolerable. Tolerable risk is not equated with
acceptability; it refers to a willingness to live with a risk so as to
secure certain risk benefits, and in the confidence that the risk is
being properly controlled.
Hazard analysis involves the identification and quantification of the
various hazards (unsafe conditions) that exist in the plant. On the
other hand, risk analysis deals with the identification and
quantification of risks, the plant equipment and personnel are
exposed to, due to accidents resulting from the hazards present in
the plant.
Hazard and risk analysis involves very extensive studies, and
requires a very detailed design and engineering information. The
various hazard analysis techniques that may be applied are hazard
and operability studies, fault-tree analysis, event-tree analysis and
failure and effects mode analysis.
Risk analysis follows as extensive hazard analysis. It involves the
identification and assessment of risks; the neighbouring
populations are exposed to as a result of hazards present. This
requires a thorough knowledge of failure probability, credible
accident scenario, vulnerability of population’s etc. Much of this
information is difficult to get or generate. Consequently, the risk
analysis is often confined to maximum credible accident studies.
7.5.2 Common definitions
The common terms used in risk Assessment and Disaster
Management are elaborated below:
“Risk” is defined as a likelihood of an undesired event (accident,
injury or death) occurring within a specified period or under
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specified circumstances. This may be either a probability depending
on the circumstances.
“Hazard” is defined as a physical situation, which may cause
human injury, damage to property or the environment or some
combination of these criteria
“Hazardous substance” means any substance or preparation,
which by reason of its chemical or physic chemical properties or
handling is liable to cause harm to human beings, other living
creatures, plants, micro-organisms, property or the environment
“Hazardous process” is defined as any process or activity in
relation to an industry which may cause impairment to the health
of the persons engaged or connected therewith or which may result
in pollution of their general environment.
“Disaster” is defined as a catastrophic situation that causes
damage, economic disruptions, loss of human life and deterioration
of health and health services on a scale sufficient to warrant an
extraordinary response from outside the affected area are
community. Disasters occasioned by man are factory fire
explosions and release of toxic gases or chemical substances etc.
“Accident” is an unplanned event, which has a probability of
causing personal injury or property damage or both.
“Emergency” is defined as a situation where the resources out pass
the demand. This highlights the typical nature of emergency; it will
be after experiences that enough is not enough in emergency
situations. Situations of these kinds are avoidable but it is not
possible to avoid them always.
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In the sections below, the identification of various hazards,
probable risks in a process industry manufacturing optical
brighteners, maximum credible accident analysis, consequence
analysis are addressed which gives a broad identification of risks
involved in the plant.
7.5.3 Hazard Identification
Identification of hazards in the synthetic chemicals organic plant is
of primary significance in the analysis, quantification and cost
effective control of accidents involving flammable compounds. A
classical definition of hazard states that hazard is not in fact the
characteristic of system/plant/storage that presents potential for
an accident. Hence, all the components of a system/ plant/ process
need to be thoroughly examined to assess their potential for
initiating or propagating an unplanned event/sequence of events
which can be termed as an accident.
Typical schemes of predictive hazard evaluation and quantitative
risk analysis suggest that hazard identification step plays a key role
in estimation of probability of an unexpected event and its
consequences from the basis of quantification of risk in terms of
damage to property, environment or personal. Therefore the type,
quantity location and conditions of release of a toxic or flammable
substance have to be identified in order to estimate its damaging
effects, the area involved, and the possible precautionary measures
required to be taken.
Some of the hazard identification procedures are as follows:
a) Fire Explosion and Toxicity Index (FETI) Approach;
b) HAZOP studies
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c) Maximum Credible Accident and Consequence Analysis
(MCACA);
7.5.3.1 Identification of Major Hazards from the unit
The Hazard identification process adopted is to identify hazardous
chemicals as per the statutory requirements of Manufacture
storage and import of Hazardous Chemical Rules, 1989
The identified chemicals for the risk assessment are presented in
the following Table 7.3
Table 7.3
List of Raw materials and Inventory
S.No Raw material Nature
of storage
Physical Form
Maximu
m storage quantity
Kgs
CAS NO
1 1,3 cyano hexane dione
Bags Solid 117.0 504-02-9
2 1,3
Dichloroacetone carboys Solid 771.8 534-07-6
3 2-Methyl
piperazine Bags Solid 74.4 109-07-9
4 3 Nitro Aniline Bags Solid 217.8
99-09-02
5 3-Chloro,4-Fluoro
aniline carboys Solid 1314.3 367-21-5
6 Acetic acid Tank Liquid 8093.5
64-19-7
7 Acetone Drums Liquid 5217.6
67-64-1
8 Acetonitrile Drums Liquid 1509.6
75-05-8
9 Acetyl chloride Drums Liquid 16.1
75-36-5
10 Ammonia Cylinder Gas 467.2
7664-41-7
11 Ammonium
Thiocynate Bags Solid 4228.9 1762-95-4
12 Benzyl Chloride Drums Liquid 228.7
100-44-7
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13 Caustic soda
Flakes bags Solid 1552.3 1310-73-2
14 Carbon Bags Solid 789.9
7440-44-0
15 Caustic lye Tank Liquid 3193.2
1310-73-2
16 Chlorine gas Cylinder Gas 4075.8
7782-50-5
17 Chloroform Drums Liquid 635.0
67-66-3
18 Dicyclopentadione Drums Liquid 233.5
77-73-6
19 Diethyl Sulphate Drums Liquid 1892.3
64-67-5
20 Diethylether Drums Liquid 792.3 60-29-7
21 Di methyl Amine Drums Liquid 3.0
124-40-3
22 Dimethyl
Formamide Drums Liquid 4296.1 68-12-2
23 Di Methyl
Sulphoxide Drums Liquid 126.0 67-68-5
24 EDTA Bags Solid 4.6
139-33-3
25 Eichlorohydrin Drums Liquid 3.1
106-89-8
26 EMME Drums Liquid 2022.0
87-13-8
27 Ethanol Tank Liquid 17941.4
64-17-5
28 Ethyl acetate Drums Liquid 28.1
141-78-6
29 Formic Acid
(85%) Drums Liquid 144.5 64-18-6
30 Geranyllinaliol Drums Liquid 208.5
24034-73-9
31 Guaianyl Thiourea Bags Solid 725.4
2114-02-5
32 Guaicol Drums Liquid 567.0
90-05-1
33 Gumrosin Drums Solid 6854.4
8050-09-7
34 HCl Tank Liquid 5767.8
7647-01-0
35 Hydrazine Hydrate Drums Liquid 1628.0
10217-52-4
36 Hydrose Drums Solid 73.0
7775-14-6
37 Hyflow Bags Solid 77.9
68855-54-9
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38
Hypo phosphoric
acid carboys Solid 120.8 7803-60-3
39 Isopropyl alcohol Tank Liquid 5877.0
67-63-0
40 Iron Bags Solid 211.9
7439-89-6
41 Iso Butyl chloride Drums Liquid 118.4
513-36-0
42
Light Liquid
Paraffin Tank Liquid 6157.0 8012-95-1
43 Liquid ammonia Tank Liquid 7717.1
1336-21-6
44 Lomefloxcin Acid Carboy Solid 160.8
100501-62-0
45 Menadione Bags Solid 93.8
58-27-5
46
Methane Sulphonic
acid Drums Liquid 126.0 75-75-2
47 Methanol Tank Liquid 19338.1
67-56-1
48 Methyl Iodide
Containe
rs Liquid 8.3 74-88-4
49 Mono Ethylamine Drums Liquid 1641.2
75-04-7
50 N-Butanol Drums Liquid 707.4
71-36-3
51 n-Hexane Tank Liquid 1510.5
110-54-3
52
n-Methyl
Piperazine Drums Liquid 4418.3 109-01-3
53
n-Sulphyl-3-chloro
hydrochloride Carboy Solid 401.1 1206492-70-0
54 Palladium Carbon
Plastic
tins Solid 1898.5 7440-05-3
55
Para Chloro Benzyl
Cyanate Drums Liquid 13.7 140-53-4
56 PEG Carboy Liquid 21.0
25322-68-3
57 phenyl hydrazine hydrochloride
Bags Solid 32.7 59-88-1
58
Phosphorus
oxychloride carboys Liquid 195.0 10025-87-3
59
Phosphous tri
Bromide Drums Liquid 52.9 7789-60-8
60 Piperzine Bags Solid 196.0
110-85-0
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61 Potassium Iodide Drums Solid 1922.4
7681-11-0
62
Potassium tert-
butoxide Bags Solid 30.9 865-47-4
63 Pthalic Anhydrate Bags Solid 137.6
85-44-9
64 Pyridine Drums Liquid 24.0
110-86-1
65
Sodium
bicarbonate Bags Solid 39.5 144-55-8
66 Sodium carbonate Bags Solid 174.4
497-19-8
67 Sodium Chloride Bags Solid 1933.7
7647-14-5
68 Sodium Hydride Bags Solid 83.4
7646-69-7
69 Sodium hydroxide Bags Solid 5.5
1310-73-2
70 Sodium Sulphate Bags Solid 68.7
7757-82-6
71 Stearic acid Bags Solid 11.3
57-11-4
72 Sulfuric acid Tank Liquid 5526.9
7664-93-9
73
Tertiary Butyl
Ammonium
Bromide
Bags Solid 54.3 1643-19-2
74 Tetra hydro furan Drums Liquid 846.5
109-99-9
75 Thiourea Bags Solid 463.1
62-56-6
76 Toluene Tank Liquid 6857.9
108-88-3
77 Xylene Drums Liquid 1404.8
1330-20-7
78 Zinc acetate Bags Solid 44.6
557-34-6
Table 7.4
List of hazardous chemicals (listed in part II of schedule I of
MIHS Rules)
S.
No Raw material
Physical
form
Type of
hazard
Maximum Storage
quantity Kgs
Threshold
Quantity
(Rule 5,7,9 and
13 &15
Threshold
Quantity
(Rule 10 to 12
Level
of Hazard
1 Acetonitrile Liquid Flammable 1509.6 Not
specified Not
specified Level 1 Hazard
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2 Acetic acid Liquid Flammable 8093.5 Not
specified Not
specified Level 1 Hazard
3 Acetone Liquid Flammable 5217.6 Not
specified Not
specified Level 1 Hazard
4 Ammonia Liquid Toxic,
corrosive 467.2 50T 500T
Level 1
Hazard
5 Benzyl chloride Solid Flammable 228.7 Not
specified Not
specified Level 1 Hazard
6 Chlorine Gas Toxic 4075.8 Not
specified
Not
specified
Level 1
Hazard
7 Chloroform Liquid Toxic 635.0 Not
specified Not
specified Level 1 Hazard
8 Dimethylamine Liquid Flammable 3.0 Not
specified Not
specified Level 1 Hazard
9 DMSO Liquid Flammable 126.0 Not
specified
Not
specified
Level 1
Hazard
10 Epichlorohydrin Liquid Flammable 3.1 Not
specified Not
specified Level 1 Hazard
11 Ethanol Liquid Flammable 17941.4 Not
specified Not
specified Level 1 Hazard
12 Ethylacetate Liquid Flammable 5.6 Not
specified
Not
specified
Level 1
Hazard
13 Formic acid Liquid corrosive 144.5 Not
specified Not
specified Level 1 Hazard
14 HCl Liquid corrosive 5767.8 25 T 250T Level 1
Hazard
15 Isopropyl alcohol
Liquid Flammable 5877.0 1500T 10000T Level 1 Hazard
16 Methanol Liquid Flammable 19338.1 Not
specified Not
specified Level 1 Hazard
17 n-Butanol Liquid Flammable 1510.5 Not
specified
Not
specified
Level 1
Hazard
18 n- Hexane Liquid Flammable 4418.3 Not
specified Not
specified Level 1 Hazard
19 Phenyl
hydrazine
hydrochloride
Solid Toxic 195.0 Not
specified
Not
specified
Level 1
Hazard
20 Phosphorous oxy chloride
Liquid corrosive 52.9 Not
specified Not
specified Level 1 Hazard
21 pyridine Liquid Flammable 39.5 Not
specified
Not
specified
Level 1
Hazard
22 Sodium
Hydroxide Solid Corrosive 707.4
Not specified
Not specified
Level 1 Hazard
23 Tetra
hydrofuran Liquid
Flammable /toxic
846.5 Not
specified Not
specified Level 1 Hazard
24 Toluene Liquid Flammable 6857.9 Not
specified
Not
specified
Level 1
Hazard
25 Thiourea Solid Toxic 463.1 Not
specified Not
specified Level 1 Hazard
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Note :
Level I Hazard: Chemical is listed in schedule of chemicals but
threshold limit did not crossed 1st threshold or 2nd threshold limit as per
the schedule I of MSIHC Rules 2000
The Physical properties of the key chemicals stored are presented in the
following Table 7.5
Table 7.5
Physical properties & Hazard characteristics of Key Raw
materials
S.No Name of the
Material
Boiling
point oC
Flash
Point in oC
Explosive
Limits
volume %
in air
NFPA Rating
Health Fire
recativi
Reactivi
ty 1 Acetic acid 118.1 39 4-19.9 2 2 0
2 Acetone 55.6 -17.8 2.5-12.8 2 3 0
3 Acetonitrile 81.6 2 3-16 3 3 0
4 Ammonia -28 - 15-28 3 1 0
5 Caustic Lye 1390 - - 3 0 1
6 Diethyl ether 34.6 -40 1.8-4.8 1 4 1
7 Dimethyl amine 6.9 -50 2.8-14.4 3 4 0
8 Dimethyl
sulfoxide 189 89
3.0-3.5 2 2 0
9 Ethanol 78.2 12 3.3-19.0 2 3 0
10 Ethyl aceate 77 7.2 2.2-9.0 1 3 0
11 Hydrochloric acid 108.5 - - 3 0 1
12 Hexane 69 -26 1.2-7.7 2 3 0
13 Isopropyl alcohol 82.5 12.77 2-12.7 1 3 0
14 Methanol 65.5 16 6-3-6.5 1 3 0
15 n- Butanol 117.4 28.9 1.4-11.2 1 3 0
16 Pyridine 115.4 17 1.8-12.4 2 3 0
17 Tetrahyro furan 65 -14.5 1.8-11.8 2 3 1
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18 Toluene 110.6 4.4 1.2-6.7 2 3 0
The interpretation of “The Manufacture storage and import of
hazardous chemicals Rules” issued by the ministry of Environment
and Forests, GOI which guides the preparation of various reports
necessary for safe handling and storage of chemicals shows that
the present object requires to prepare safety reports before
commencing operations and risk assessment is not mandatory .
The applicability of various rules is presented in Table 7.5
The chemical reactions involved in the process do not involve the
pressure temperature conditions in combination and does not lead
to any run any reactions hence a cursory HAZOP was conducted
and systematic emergency plan is presented
Safety measures for Transportation, Storage & Handling of
chemicals
� Solvent is proposed to be received by road tankers and stored in
barrels.
� Solvent unloading standard procedure will in place and will be
implemented for safe unloading of road tanker.
� Static earthing provision will be made for tanker unloading.
� Drum handling trolleys will be used for transportation of drums up
to plant.
� Muffler on the silencer of the tanker during entering in factory
premises.
� Display Boards will be provided on all storage tanks which
includes the name of the chemicals, stored Material of
construction and date of painting.
� Hazardous display board and national fire prevention association
code will be displayed on storage area.
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� On-site detectors for fire based on heat &/or smoke detection with
alarm system will be provided as required.
� Fire extinguishers will be provided as required.
� First aids boxes will also be provided at different places wherever
required.
� Water showering system will be provided to the flammable
chemicals storage area, wherever required to avoid the
vaporization due to increase in atmosphere temperature.
� Area will be declared as “NO SMOKE ZONE”.
7.6 Fire& Explosion Index (F&EI):
7.6.1 Methodology
Dow Chemical Company issued a guideline for hazard
determination and protection. By this method a chemical process
unit is rated numerically for hazards. The numerical value used is
the Fire and Explosion Index (F&EI) which is most widely used for
hazard evaluation in chemical process industries.
The guide applies to process unit only and not to auxiliary units
such as power generating stations, plant water systems, control
rooms, fired heaters, structural requirements, corrosive nature of
material handled and personal safety equipment. These are
regarded as basic features that do not vary according to the
magnitude of the fire and explosion hazard involved. The guide also
does not cover the processing and handling of explosives such as
dynamite, TNT etc.
7.6.2 Computation of F&EI
The computation of fire and explosion index of each unit is based
on the material factor. This is a measure of the intrinsic rate of
potential energy release from fire explosion of most hazardous
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material or mixture of materials present in significant quantity,
whether it is raw material, intermediate, product, solvent etc., by
combustion or chemical reaction. “In significant quantity” here
means such quantity that the hazard represented by the material
actually exists. The Nationality Fire Protection Agency of USA
(NFPA) have specified standard values for material factor which
should be used for F&EI calculations and are available in DOW’s
hazard classification guidein case it is not readily available, it can
be calculated using the heat of combustion, flammability indices
etc.
General process hazard are factors that play a primary role in
determining the magnitude of loss of incident. It takes into account
the nature of the reaction, ventilation of the unit, accessibility of
the unit, drainage facilities etc., special process hazards are factors
that contribute primarily to the probability of a loss incident. They
consist of specific process conditions that have shown themselves
to be major causes of fire and explosion incidents. It takes into
account toxicity of the material, operating pressure, operation near
flammable range, quantity of material, joints and packing, use of
hot oil exchange system etc., The F&EI calculated as a product of
material factor, general process hazard factor, and special process
hazard factor.
7.6.3 Hazard Ranking
The hazard ranking based on F&EI value is as follows
Table 7.6 Degree of Hazard for F&EI
F&EI Index Range Degrees of Hazard
1-60 Light
61-96 Moderate
97-127 Intermediate
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128-158 Heavy
159 & above Severe
The estimated values of F&EI reflect light hazard in view of the low
volume of chemicals.
The fire and explosion index evaluation can be very useful in
developing plant layouts or adding equipment and buildings to
existing plants. Evaluation of the F&EI calculations and layout
considerations will result a safe operable, maintainable and cost
effective arrangement of equipment and buildings.
7.6.3.1 Maximum Credible Accident Analysis and Its Mitigation
Measures
A Maximum Credible Accident (MCA) can be characterized as the worst
credible accident. In other words: an accident in an activity, resulting in
the maximum consequence distance that is still believed to be possible.
A MCA-analysis does not include a quantification of the probability of
occurrence of the accident. Another aspect, in which the pessimistic
approach of MCA studies appears, is the atmospheric condition that is
used for dispersion calculations.
The Consequence Analysis has been done for selected scenarios by
ALOHA (version 5.4.4) of EPA. The details of software used for MCA
analysis are described below.
� A computer based version ALOHA 5.4.4 is used to calculate toxic
and explosive effect of the accidental release of liquid chemicals
within the plant area.
� ALOHA (Areal Locations of Hazardous Atmosphere) is a computer
program designed especially for use by people responding to
chemical release as well as for emergency planning and training.
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� ALOHA was jointly developed by the National Oceanic and
Atmospheric Administration (NOAA) and the Environment
Protection Agency (EPA).
� The mathematical model is based on the Emergency Response
Planning Guidelines (ERPGs) which gives Toxic Levels of Concern
(LOCs) to predict the area where a toxic liquid concentration
might be high enough to harm people.
� ALOHA models key hazards-toxicity, flammability, thermal
radiation (Heat), and over pressure (expansion blast force)-
related to chemical releases that result in toxic gas dispersion, fire
and/or explosion.
7.6.3.2 Heat Radiation & Vapour cloud Fire distances of
Hazardous Storages
Following table gives the bulk storages of chemicals after expansion
activity.
Table 7.7
Bulk Storages after expansion
Existing tanks
S.NO Name of the chemicals
Capacity (KL)
MOC
No. Of Tanks
Tank Dia
(m)
Tank Height
(m)
Remarks
1 Methanol
60
MS
1 X 10 KL
5 x 10 KL
3.8
3.8
1.9
1.9 Below ground
2 Toluene 10 MS 1 X 10 KL
3.8 1.9
Below ground
3 Rectified
Spirit 17.5
MS 1 X 10 KL
1 x 7.5 KL 3.8
3.8
1.9
1.9
Below ground
4 IPA 22 MS 1 X 11 KL
1 x 11 KL
3.9
3.9
1.9
1.9
Below ground
5 Furnace Oil 22 MS 1 X 5 KL
1 x 17 KL
1.25
3.0
2.25
2.7 Above ground
6 Ammonia 10 MS 1X 10 KL
3.5 1.9 Above ground
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6 HCl 18 FRP 1 X 18 KL 3.5
2.6
Above ground
7 Sulphuric
Acid 35
MS,
HDPE,
FRP
1 X 10 KL
1 x 10 KL
1 X 15 KL
3.3
3.5
4.0
2.0
2.0
2.22
Above ground
9 Acetic Acid 77 FRP,
HDPE
4 X 19.25
KL 3.5 2.6
Above ground
10 CS Lye 10 MS 1 X 10 KL
3.5 2.0 Above ground
11 Weak
Piperzine 15
MS 1 X 15 KL 4 2.65
Above ground
Proposed tanks
12 Acetic acid 60 MS 2x30 KL
4.5 4.5 Above ground
13 Sulphuric
acid 20
MS 1x20 KL 3.5 3.5
Above ground
14 Rectified
Spirit 10
SS 1 X 10 KL 3.5 2.0
Above ground
Out of the above, Toluene, Methanol, Ethanol, IPA are proposed to
be stored underground. C.S Lye, Weak Piperazine, Acetic acid,
Sulphuric acid, Rectified spirit, HCl, Ammonia and Furnace oil are
proposed to be stored in above ground tanks.
Consequences Analysis
From the proposed raw materials the following chemicals have
been taken considering their hazardous nature. The heat radiation
distances in case of pool fire for flammable storage tanks are
presented in the below Table 7.8 below
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7-20 Pridhvi Envirotech Pvt. Ltd
Table 7.8
Heat Radiation Damage Distances for storage tanks – Tank farm
S.No
Name of
Raw
material
Storage Tank Details
Scenario Details( Pool fire –
Leaking tank)
FEI
Index Tank
Capacity
(KL)
No.s Diameter
(m)
Height
(m)
Release
Rate
(Kg/min)
Heat radiation
damage distances
in m for KW/m2
10 5 2
1 Methanol 68 60 6 3.8 1.9 23.5 <10 <10 10
2 Toluene 100 10 1 3.8 1.9 24.5 <10 11 15
3 Ethanol 75 18 2 3.8 1.9 23.4 <10 <10 12
4 Isopropyl
alcohol
90 12 1 3.9 1.9 23.3 <10 <10 13
5 Acetic
acid
65 77 4 3.5 2.6 26.9 <10 <10 <10
Note:
2 kW/(sq m) -- people will feel pain after 45 seconds and receive
second degree burns after 3 minutes;
• 5 kW/(sq m) -- people will feel pain after 13 seconds and receive
second degree burns after 40 seconds; and
• 10 kW/ (sq m) -- people will feel pain after 5 seconds and receive
second degree burns after 14 seconds.
The storage is a small capacity facility and accordingly the F & E
index value is found to be moderate reflecting the threshold limits
as prescribed in MSHC rules. As can be seen, the heat radiation
distances are confined to plant area only.
Other hazardous chemicals stored in drums and vapour cloud fire
distances are estimated using ALOHA model and same are
presented in the Table 7.9 Below
Table 7.9
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Liquid storages in Drums – Vapour cloud Fire distances
S.No
Name of
Raw
material
Storage Tank Details Scenario Details
FEI
Index
Storage
Invento
ry kgs
Each
Drum
capacity
NO. Of
Drums
Relea
se
Rate
(Kg/
sec)
Vapour cloud
fire distance
Red Oran
ge
Yell
ow
1 Acetone 95 2500 100 Kgs 25 1.67 11 - 13
2 Tetra
hydrofuran
108 300 50 Kgs 6 0.83 22 - 62
3 Chloroform 90 250 50 Kgs 5 4.17Kg
/min
33 359 -
7.6.3.3 Toxic chemicals storage and toxic impact distances:
Following chemicals are classified as toxic chemicals used by the
company. Toxic influence distances are estimated using ALOHA
model in case of Drum Leakages and presented below
Nak
od
a C
hem
icals
Lim
ited
E
nv
iro
nm
en
tal
Imp
act
Ass
ess
men
t R
ep
ort
7-2
2
Pri
dh
vi
En
vir
ote
ch P
vt.
Ltd
Tab
le 7
.10
Toxic
th
reat
zo
nes o
n r
ele
ase o
f ch
em
icals
S.N
o
Nam
e o
f
the s
olv
en
t
Sto
rag
e
cap
acit
y
Scen
ario
Deta
ils
Rele
ase
rate
(kg
/m
in)
AEG
L-3
Red
(m
)
AEG
L-3
Red
(p
pm
)
AEG
L-2
Oran
ge
(m
)
AEG
L-2
Oran
ge
(p
pm
)
AE
GL-1
Yello
w(m
)
AEG
L-1
Yello
w
(p
pm
)
1
Acetic a
cid
77
3.7
8
49
250
224
35
666
5
2
Meth
anol
60
10.8
16
7200
34
2100
117
530
3
Eth
yl aceta
te
50
50
23
10000
65
1700
79
1200
4
Tolu
ene
10
8.9
3
13
3700
35
560
197
67
5
Chlo
rform
100
100
53
3200
574
64
- -
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Note :
AEGL-1 (Yellow zone): The airborne concentration of a substance above
which it is predicted that the general population, including susceptible
individuals, could experience notable discomfort, irritation, or certain
asymptomatic non sensory effects. However, the effects are not disabling
and are transient and reversible upon cessation of exposure.
AEGL-2 (Orange zone): The airborne concentration of a substance above
which it is predicted that the general population, including susceptible
individuals, could experience irreversible or other serious, long-lasting
adverse health effects or an impaired ability to escape.
AEGL-3 (Red zone): The airborne concentration of a substance above
which it is predicted that the general population, including susceptible
individuals, could experience life threatening health effects or death.
7.6.3.4 Analysis of quantitative risk assessment data:
Based on the above quantitative risk assessment, following
conclusions can be made.
� Flammability threat zones and heat radiation zones for
flammable chemicals are within the plant premises
� FEI index for flammable chemicals is moderate for all chemicals
� Storage quantities of flammable chemicals are well below the
threshold quantities
� Toxic threat zones (red category ) is within factory premises for
all toxic chemicals
� Toxic threat zone (Orange category) is going beyond factory
premises for 1 chemical
� However Yellow zone concentrations are well within TLV values
of the chemicals
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7.6.3.5 Health Hazards from exposure to hazardous substances and
control measures.
Existing hazards considered from operational/equipment manuals.
Detailed Hazard identification and health based risk assessment of
various operations and processes are carried out.
Based on analysis 5 chemicals are identified as toxic chemicals in
liquid form. Toxic concentrations distances are determined based on
the modelling data and presented.
RISK MITIGATIVE MEASURES
� Material data sheets shall be available at user places.
� Engineering controls for leak detection and control of storage
tanks
� Availability of neutralization agents to control impact of any
leakages of chemicals
� Closed material handling system through pipes
� Spill control kits and procedures are established.
� Good Manufacturing practices and housekeeping practices are
established.
� Provide personal protective equipment (PPE) such as gloves,
goggles and respirators.
� Operators training on control measures by on job
training/induction training.
� Carry out practice drills for cleaning up spills safely – do this
before any spillages happen.
� Annual health checks are being carried out for all employees.
� Information to District authorities to tackle off-site emergency
situations
� Ensuring availability of antidotes in the plant and nearby public
hospital to tackle any off-site emergency situation
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7.6.4 Hazard and Operability Study (HAZOP)
Safety and reliability of modern processing plant can be improved by
using procedures that recognize and eliminate potential problems in
the design stage. This is especially important because of the
increasing need to operate the different units, for economic reasons,
more closely to known risk situations. Hence, it requires refined
methods like HAZOP study technique for identifying hazardous
situations and problems and eliminating them at the design stage.
Based on process reactions, a list of process reactions were identified
for taking additional care precautions and presented in Table 7.11
Table 7.11 Hazardous processes and precautions suggested
Unit
process
Chemicals
involved
Equipment
&utilities
Temp/
Pressure
Emissio
ns Safety measures
Product : ACETAZOLAMIDE
Acetazolam
ide
DTA
GLR 50c - 1060c
Ammoni
um
Sulphate
In this stage Hydrazine
Hydrate is used by
converting into sulphate
salt by treating it with
Conc.H2So4. Once it forms
sulphate there will be no
free hydrogen. (Free
Hydrogen is present due
to decomposition of
Hydrogen Hydrate) We
keep excess H2So4 to avoid accident due to free
Hydrogen during heating.
NH2 . NH2 . H2O + H2So4
H2N . NH2 . H2So4.
Stage-I
1) Hydrazine
Hydrate
Stage-III
1) Chlorine Gas GLR 00c - 100c Cl2 gas
In this stage chlorine gas
(Cl2) is passed into
reaction mass through
sparger at 5-80c. The
excess of gas is absorbed
in closed scrubber
containing C.S. Lye
solution. During the gas
purging the scrubber is
kept always in alkaline
condition, so that no Cl2
gas will escape in
atmosphere.
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Unit
process
Chemicals
involved
Equipment
&utilities
Temp/
Pressure
Emission
s Safety measures
Product : Norfloxacin Q-Acid
NFX /
Q.Acid
SSR 1200c -
2600c
Ethyl
alcohol
The High
temperature is
controlled carefully
by temperature
sensor. Stage-I
1) 3-Chloro 4-
Flouro Aniline
2) Ethoxy Methylene
Melonic Ester
Unit
process
Chemicals
involved
Equipment
&utilities
Temp/
Pressure
Emission
s Safety measures
Product : MENATETRENONE
Stage-I 1) Dicyclo
pentadiene SSR
1550c -
1600c
It is a dimer. To get
Monomer (Cyclo
Pentadiene) it was
cracked about 160-
1700c U/N2 gas.
During this operation
same unpleasant
smell of Cyclo
pentadiene will come,
which is absorbed in
KMnO4 solution. In
KMnO4 solution it is
oxidized to Co2 and
Water with no smell.
Stage-II 1) Phosphorus tri
bromide GLR
00c – (-)
200c
Bromine
Fumes
It is fuming material
at room temperature
and above. Before
unloading the
container is cooled to
about 150c. Then is
carefully charged in
to the reaction Mass
at about -180c to -
220c. The reaction is
carried out at -180c
to -220c.
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Unit
process
Chemicals
involved
Equipment
&utilities
Temp/
Pressure
Emission
s Safety measures
Product : 2-(2-Methoxy Phenoxy) – Ethylamine
005 Anisole
Stage-I
1)Acetonitrile
SSR
500c -
1050c
1050c -
1350c
Ammonia
Gas
In this stage, the
acetonitrile and Mono
amino ethanol
treated at reflux and during reflux
ammonia gas is
liberated which is
absorbed in dilute
HCl solution.
CH3CN+H2N-CH2-
CH2-OH N
CH3-C + NH3
O
Oxazoline
Ammonia
Absorbed In
dilute HCl
2) Mono amino
ethanol
3) Zinc acetate
Unit
process
Chemicals
involved
Equipment
&utilities
Temp/
Pressure
Emission
s Safety measures
Product : Az elastin -1
Stage-III Sodium hydride SSR
Sodium Hydride is
moisture sensitive.
The reaction mass
M/C must be below
0.1% while charging
sodium hydride in to
the reaction mass,
and surrounding
should be kept dry.
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Unit
process
Chemicals
involved
Equipment
&utilities
Temp/
Pressure
Emission
s Safety measures
Product : Ecabet Sodium
Stage-I
1.Gum Rosin
2.Palladium
Carbon
SSR 250-2600C Hydrogen
Gas
The Gum Rosin is
dehydrogenated in
presence of catalytic
amount of pd/c under
nitrogen gas passing
at 250-2600C. The
liberated hydrogen gas is absorbed in
water. The high
temperature is
controlled by Temp.
Sensor.
Unit
process
Chemicals
involved
Equipment
&utilities
Temp/
Pressure
Emission
s Safety measures
Product : Stearic Hydrazide
Stage-II
1. Stearic Acid
2. Methanol
3. Hydrazine
Hydrade
4. Ethyl Acetate
GLR/SSR 65-700C
In this reaction
hydrazine is used to
convert methyl
stearate to stearic
hydrazide in ethyl
acetate medium by
warming. The excess of hydrazine is
reacted with ethyl
acetate in the same
reaction and get
neutralized.
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7.6.5 HAZOP WORK SHEETS & SAFETY MEASURES RECOMMENDED
Following work sheets shall be used for development of safety
measures
Process Parameter: Raw material flow
Table 7.12 HAZOP Work Sheet – Raw Material Flow
S.
No
Deviati
on Causes
Consequ
ences
Safety
Features/Measures Remarks
1 No Flow No supply
Malfunctioning of
pump
Power failure
No
Reaction
Operation control
devices and
emergency plant shut
down procedure,
alarm system etc.
Alternative Automatic
power source
Inspect
Operations
Frequently
2 Less
Flow
Malfunctioning of
pump
Malfunctioning of
Shut off valve
Valve on
charging line not
opened
Operation
al trouble
in
reactors
Operation control
devices and
emergency plant
shutdown procedure,
alarm systems etc.
Check the
shut off valve.
Ensure the
feed valve is
opened
3 More
Flow
Malfunction of
control valve
Operation
al trouble
in reactor
Flow regulators,
Excess flow diversion
devices to Alternative
storage or Flare etc.
Flow control
devices
inspection and
examination
and
maintenance
will be
continuous
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II) Process Parameter: Pressure
Table 7.13 HAZOP Work Sheet - Pressure
S.No Deviatio
n Causes
Consequenc
es
Safety
Features/Measur
es
Remarks
1 No
Pressure
-- -- -- Not
Envisaged
during
operation
2 Low
Pressure
Malfunctioning
of pump
Malfunctioning
of Shut off
valve
Valve on
charging line
not opened
Leakages in
pipe line
Operational
trouble in
reactors
Periodic inspection
&Examination,
Maintenance
Leak detect system
Shut off valve
Low pressure
alarm/indicators
shall be provided
Pipe line and
flow control
devices
examined
frequently
3 High
Pressure
High
Temperature
Excess supply
Malfunction of
control valve
Operational
trouble in
reactor
Rupture of
pipe line
Fire or
Explosion
Periodic inspection
&Examination,
Maintenance
Pressure relief
system
Automatic flow
diverter
Alternative storage
system
Pipe line and
flow control
devices
examined
frequently
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(III) Process Parameter: Temperature
Table 7.14 HAZOP Work Sheet: Temperature
S.No Deviation Causes Consequen
ces
Safety
Features/Measur
es
Remarks
1 No
Temperatu
re
-- -- -- Not
envisaged
during
operation
2 Low
Temperatu
re
Malfunctio
ning of
Temp.
Indicator
External
cooling
-- Calibration of
Temperature
indicators, periodic
Inspection
Examination
Examine the
pipe line and
control
devices
working
conditions
frequently
3 High
Temperatu
re
Malfunctio
ning of
Temp.Indi
cator
External
fire/Heatin
g
Rupture/
failure in
pipe line
Calibration of
Temp.Indicator,
periodic Inspection
Examination
Thermal Insulation
Around the pipe
Radiation
Detectors/Sensors
will be provided
Examine the
pipe line and
control
devices
working
conditions
frequently
7.6.6 Hazard Factors
A study of past accident information provides an understanding of
failure modes and mechanisms of process and control equipment and
human systems and their likely effects on the overall plant reliability
and safety.
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Some of the major contributing factors for accidents in chemical
industries are:
Table 7.15
Contributing factors for accidents
S.No Contributing Factor Per cent Loss
1 Equipment design faults 41
2 Process design faults 10
3 Operator errors 31
4 Maintenance deficiencies 12
5 Material Hazards 6
A study AICHE (1972) indicates that majority of equipment of
component failures involve compressors, furnaces and heat
exchangers as there are lesser opportunities to take them off for
maintenance. The frequency of equipment or component failures is
observed as follows:
Table 7.16 Failure frequency statistics of key equipment
S.No Equipment Frequency (%)
1 Compressors 30
2 Furnaces 18
3 Heat Exchangers 17
4 Process Vessels 18
5 Others 17
However, failures of storage vessels and those during transportation
have been reported more frequently than cases of plant failures. The
failure rate of various equipment in a typical power plant is provided
in the following table.
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7.6.7 Equipment Failure Rates
(Data from reliability Technology by A.E.Green and J.R Bourne,
Copyright C,1972,reproduced with permission of John Wiley and
Sons,Inc)
Table 7.17
Equipment failure rates
Equipment Failure
Rate(Failures/106h)
Electric Motors 10
Transformers(<15 kv) 0.6
Transformers(132-400k V) 0.7
General, (33k V) 2
Circuit breakers 10
Pressure vessels(general) 3
Pressure vessels
(High standard)
0.3
Pipes 0.2
Pipe joints 0.5
Ducts 1
Gaskets 0.5
Bellows 5
Diagrams(metal) 5
Diagrams(Rubber) 8
Unions and junctions 0.4
Hoses(heavily stressed) 40
Hoses(Lightly stressed) 4
Ball bearings(heavy duty) 20
Ball bearings(Light duty) 10
Roll bearings 5
Sleeve bearings 5
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Shafts(heavily stressed) 0.2
Shafts(Lightly stressed) 0.02
Relief valves leakage 2
Relief valves blockage 0.5
Hand-operated valves 15
Control valves 30
Ball valves 0.5
Solenoid valves 30
Rotating seals 7
Sliding seals 3
‘O’ring seals 0.2
Couplings 5
Belt drives 40
Spur gears 10
Helical gears 1
Friction clutches 3
Magnetic clutches 6
Fixed orifices 1
Variable orifices 5
Nozzle and flapper assembles: blockage 6
Nozzle and flapper assembles:breakage 0.2
Filters: blockage 1
Filters: Leakage 1
Rock and pinion assembles 2
Knife edge fulcrum: wear 10
Springs(heavily stressed) 1
Springs(Lightly stressed) 0.2
Hair springs 1
Calibration springs: creep 2
Calibration springs: Breakage 0.2
Vibration mounts 9
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Mechanical joints 0.2
Grub Screws 0.5
Pins 15
Pivots 1
Nuts 0.02
Bolts 0.02
Boilers(all types) 1.1
Boilers feed pumps 1012.5
Cranes 7.8
7.6.8 Common Causes of Accidents
Engineering and Instrumental
Based on the analysis of past accident information, common causes of
major chemical plant accidents are identified as:
• Poor house keeping
• Improper use of Tools, equipment, facilities
• Unsafe or defective equipment facilities
• Lack of proper procedures
• Improving Unsafe procedures
• Failure to follow prescribed procedures
• Jobs not understood
• Lack of awareness of hazards involved
• Lack of proper tools, equipment, facilities
• Lack of guides and safety devices
• Lack of protective equipment and clothing
7.6.9 Failures of Human Systems
Na assessment of past chemical accidents reveals human factor to the
cause for over 60% of the accidents while the rest are due to other
plant component failures. This percentage will increase if major
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accidents alone are considered for analysis. Major causes of human
failures reported are due to:
� Stress induced by poor equipment design, unfavourable
environmental conditions, fatigue, etc.
� Lack of training in safety and loss prevention
� Indecision in critical situations.
� Inexperienced staff being employed in hazardous situations
Often, human errors are not analysed while accident reporting and
accident reports only provide information about equipment or
component failures. Hence, a great deal of uncertainty surrounds
analysis of failure of human systems and consequent damages.
The number of persons/materials are potentially exposed to a specific
hazard zone is a function of the population density and distribution near
the accident location. The failure rate data and ignition sources of
major fires are presented in the following Tables 7.17 and 7.18
Table 7.18 Ignition Sources of Major Fires
S. No Ignition source Percent
1 Electrical (wiring of motors) 23%
2 Smoking 18%
3 Friction 10%
4 Overheated material 8%
5 Burner flames 7%
6 Combustion sparks 5%
7 Spontaneous ignition 4%
8 Cutting & Welding 4%
9 Exposure (fires jumping into new areas) 3%
10 Incendiarism (fires maliciously set) 2%
11 Mechanical sparks 2%
12 Molten substances 1%
13 Chemical actions 1%
14 Static sparks 1%
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15 Lightening 1%
16 Miscellaneous 1%
7.7 Disaster Management Plan
7.7.1 Introduction
A disaster is a catastrophic situation in which suddenly, people are
plunged into helplessness and suffering and, as a result, need
protection, clothing, shelter, medical and social care and other
necessities of life.
Disasters can be divided into two main groups In the first, are disasters
resulting from natural phenomena like earthquakes, volcanic eruptions,
storm surges cyclones, tropical storms. Floods, avalanches, landslides,
and forest fires. The second group includes disastrous events
occasioned by man, or by man’s impact upon the environment.
Examples are armed conflict. Industrial accidents, radiation accidents,
factory fires, explosions and escape of toxic gases or chemical
substances, river pollution, mining or other structural collapses, air, sea
rail and road transport accidents and can reach catastrophic
dimensions in terms of human loss.
There can be no set criteria for assessing the gravity of a disaster in
the abstract since this depends to a large extent on the physical,
economic and social environment in which it occurs. However, all
disasters bring in their wake similar consequences that call for
immediate action, whether at the local, national or international lever,
for the rescue and relief of the victims. This includes the search for the
dead and injured, medical and social care, removal of the debris, the
provision of temporary shelter for the homeless, food, clothing and
medical supplies, and the rapid re-establishment of essential services
An emergency may be said to begin when operator at the plant or in
charge of storage of hazardous chemicals cannot cope up with a
potentially hazardous incident, which may turn into an emergency. The
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emergencies could be a major fire or explosion or release of toxic gas
or a combination of them
The proposed plant will store fuels, which are flammable in nature, and
the storage will be as per the Controller and the project is still in the
initial stages of designing. Hence a tentative disaster management
plan is prepared to be suitably modified before commissioning of the
plant.
7.7.2 Objectives of Emergency Management Plan (On-Site)
A quick and effective response during emergency can have tremendous
significance on whether the situation is controlled with little loss or it
turns into a major emergency therefore, the objectives of this onsite
emergency plan (ONSEP)
During Emergency: is to provide basic guidance to the personnel for
effectively combating such situations to minimize loss of life, damage
to property and loss of property.
• To Locate emergency and if possible to eliminate
• To minimize loss to personnel and property, in quickest time
possible
• Fire fighting equipments and safety Appliances should be made
available, in readily usable condition, in the event of emergency
• To decide for shutdown of the plant in case of emergency
• To localize the hazard/ accident
• To fix responsibilities to the persons in the plant in case of
emergencies
• To arrange rescue operations and treatment to the persons
affected
• To provide safety to other persons present in the plant at the time
of hazard
• To contain the hazard within the plant
• To get assistance from neighbouring industries under Mutual Aid,
fire Station, Hospitals etc.
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• To alert the statutory authorities concerned for further action in
case the hazard is likely to extend to the outside area of the plant
During Normal Time:
• To keep the required emergency equipment in stock at right
places and ensure their working condition;
• To provide proper guidelines to all personnel for emergency
operations and escape
• Preserve relevant records and evidence for the emergency case
and subsequent enquiry
• Investigation and remedial measures to avoid reoccurrence of the
hazard
7.7.3 Scope of ONSEP
This ONSEP is prepared for industrial emergencies like fire, explosions,
toxic releases, asphyxia and does not cover natural calamities and
societal disturbances related emergencies (like strikes, bomb threats,
civil Commissions etc.). Also, the scope this ONSEP is limited to onsite
emergencies and does not include measures for offsite Emergency
Management.
Necessary information with regards to Off Site Emergency Management
will be furnished to district authorities.
7.7.4 Methodology of Development ONSEP
The consideration in preparing this Emergency Plan includes the
following steps:
• Identification , location and assessment of hazardous incident
• Alarm and communication sequences
• Identification and deployment of personnel assigning
responsibilities]identifying assembly point, Emergency Control
Centre, Fire Fighting and Personal Protective Equipment
utilization, First aid and Medical facilities
• Emergency Plant shut down
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• Training and Rehearsal on Mock Drill
• Preparedness for Action on site
Earlier, a detailed Hazards Analysis and Risk Assessment were carried
out for the plant facilities and the hazards are quantified. The likely
location of hazards and consequences are evaluated, duly following the
standard procedure.
7.7.5 Elements of onsite Emergency Plan
Important elements considered in this plan are:
• Identification of emergencies
• Emergency organization
• Emergency facilities
• Emergency procedure
• Communications during emergency
• Rescue, Transport and Rehabilitation
• Roles and responsibilities of key personnel and essential
employees
• Mutual aid
7.7.6 Emergencies Identified
Following are the typical emergencies anticipated from this type of
industries
- Fire accidents at Bulk solvent storage & HSD areas
- Fire accidents at Boiler area, DG area
- Fire in reactors area
- Food /Water Contamination..
- Fire accidents in QC Laboratory.
- Major Spillage of solvents & HSD.
- Fire accident in scrap yard.
- Electric shocks.
- Reaction hazards in Hydrogenation area
- Hydrogen Cylinder explosion
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- Catalyst fire
The other emergencies are asphyxiation of persons, apart from risks
due to cyclonic conditions, earth quake, lightning, floods (natural
calamities), sabotage, bombing (social and other reasons) etc. which
are not under the management control.
Priority of protection in the event of an emergency is; Life and Safety
of personnel, preservation of property, restoration of normalcy.
7.7.7 Emergency Organization
The responsibilities of key personnel for emergencies are clearly
defined as follows
An emergency control room as the focal point has been earmarked.
The control room flashes information to various agencies as shown in
the chart. This is located in an area of minimum risk and close to
road. Security and Time office room is the emergency control point.
7.7.8 Emergency Facilities
a) Emergency Control Centre (ECC)
It is a location where all key personnel like Site Controller, Emergency
Coordinators can take stock of situation or can assemble and monitor
aspects related to emergency and take decisions related to emergency.
The office room is designated as ECC. In case if this area is affected,
zone security room is designated as alternative ECC.
The following information and facilities would be maintained at the ECC
Plant control room: Latest copy of Onsite Emergency Plan and Off Site
Emergency Plan (as provided by District Emergency Authority)
• Intercom Telephone
• P&T Telephone
• Telephone Directories (internal and P&T)
• Factory Layout, Site Plan
• P&I diagrams, electrical connections plans indicating locations
of hazardous inventories, sources of safety equipment, hydrant
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layout, location of pump house, road plan, assembly by points,
vulnerable zones, escape routes;
• Hazard Chart;
• Emergency shutdown procedures for generators and fuel
supply system;
• Nominal roll of employees;
• List and addresses of key personnel;
• List and addresses of first aid providers;
• List and addresses of employees trained in fire fighting;
• List and addresses of qualified trained persons;
• Material safety data sheets of raw materials;
• Duties of key personnel;
• Important addresses and telephone numbers including those of
fuel supplying company, government agencies, neighbouring
industries and other sources of help, outside experts;
The following emergency equipment is made available at alternate ECC
(Security point):
• Fire proximity suit/Gloves/Helmets;
• Hand tools suitable for pipelines (non sparking type);
• Teflon tape;
• Gas Explosion meter;
• Flame proof torches/batteries;
• Manila rope;
• Spark arrestor;
• First aid box;
• Special fire fighting information related to hydrocarbon fuels;
• Public address megaphone, hand bell, emergency torch.
b) Assembly Points
Assembly points are those locations where the persons who are not
connected with emergency operations can await either for further
instructions or for rescue transport and rehabilitation. Assembly
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point is located opposite to Security and Time Office room which is
located far away from production area.
C) Emergency control systems present
The following emergency control systems are in place in M/s. Nakoda
Chemicals Limited
1. Lightening protection for all buildings and high raised chimneys.
2. Earthing & Bonding for electrostatic hazards.
3. Closed arrangement for solvent transferring.
4. Pressure Relief system & Rupture Discs etc.
5. Earth Rite system for road tanker loading and unloading.
6. Dust collection system with proper measures from electrostatic
hazards.
7. FLP fittings at Flammable materials handling areas.
8. Product containment booth at raw material sifting.
� Addressable fire detection system.
� Fire detectors
� Smoke detectors
9. Fire protection systems :
� Portable Fire Extinguishers
10. Occupational Health Centre.
11. Safe handling procedures.
12. Spill Control kits.
d) Location of First Aid Boxes
The first aid boxes are located at the following places production
blocks, Utilities block, Service areas, administrative office, time office,
and will be under the charge of EHS in-charge.
e) Fire protection system
An elaborate fire protection system is in place in M/s. Nakoda
Chemicals Limited about 37 Nos of fire extinguishers of various types
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and 12 sand buckets placed at different locations. Fire Hydrant system
is in place to cover the entire plant including manufacturing blocks,
Bulk storage tanks and utility areas.
h) Emergency Escapes
Emergency escapes in the plant area and floor wise emergency are
conspicuously marked.
i) Wind Sock
Wind socks are located at the following locations
S.No. Location
1. Top of the new Production Block
7.8 ORGANISATION
Plant Manager is the over all in-charge of the plant operations and is
assisted by all department heads. Production activities are looked
after by both the Production Head/Managers, EHS activities by head
Safety, Health & Environment, Engineering aspects by head
(Maintenance) Plant Electrical maintenance by Electrical Engineer,
material inventory by stores head, Personnel & Administration wings,
other department heads are directly reporting to Unit Head.
7.9 MAN POWER
All Chemists/Executives/Assistants/Managers are well qualified and
experienced in finished dosage manufacturing Industry. Experience is
varying from 2 to 15 years in the similar field.
SHIFT TIMINGS
A Shift 06 Hrs - 14 Hrs
B Shift 14 Hrs – 22.00 Hrs
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C Shift 22.00 Hrs – 06.00 Hrs
General Shift 8.30 Hrs – 17.30 Hrs
7.9.1 EMERGENCY ORGANISATION
1. An Emergency Organization is constituted including Plant Manager
Production Manager, Personnel Manager, Logistics Managers,
Assistant Managers, Safety Officer, Maintenance Personnel, Process
Engineer / Project Engineer, Production Officers, Shift In –charge,
Supervisors, Chemists, and Security In-charge,. Boiler Operators,
Electricians, Vehicle Drivers, Office Staff, Security Staff, Security
Staff are included as Essential Employees.
2. Plant Manager is designated as Site Controller
3. Production Manager is designated as Incident Controller as
alternate.
All Managers are usually present during day shift are designated as Key
Personnel and Coordinate different functions during non-emergency
and emergency situation
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7.9.2 EMERGENCY ORGANISATION ROLES AND RESPONSIBILITIES
7.9.2.1 SITE CONTROLLER - Plant Manager
On knowing about Emergency at plant, he would take charge of
Emergency Management immediately. If he is away from plant, he
would reach the plant as available at Site during an emergency,
Incident Controller would ascertain the same from Security and assume
charge as Site Controller till the Site Controller arrives at the Scene and
assumes charge.
HE WILL
1. Assess the magnitude of the situation on the advice of incident
controller and decides if staff need to be evacuated from their
assembly points. He will also coordinate between various
concerned agencies.
2. Exercise direct operation control over the emergency
3. Maintain a continuous review of possible development and assess
the situation in consultation with Incident controller and other Key
personnel as to whether shutting down the plant or any section of
the plant or bring the batches to safe position
4. Liaison with senior officials of Police, Fire Brigade, Medical and
Factories Inspectorate. Provide advice on possible effects on areas
outside the factory premises through Emergency Controller (
production Officer)
5. In consultation with the Incident Controller, call for external
help/mutual aid, if required
6. Arrange through Emergency Controller flashing information to the
Inspector of Factories, APPCB and other statutory Authorities.
7. Declares conclusion of emergency in consultation with Incident
Controller
8. Prepare the investigation report giving the sequence of events and
preserve the evidence for further enquiry.
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Decides upon
9. Conclusion of emergency.
10. Keeps record of chronological events and prepare as an
investigation report and preserve evidence.
11. During non emergency time, Reviews Onsite Emergency plan
from time to time, taking into considerations of changing needs,
like product, chemicals, installations etc changes among persons
handling important assignments, issue of correction slips to plan,
Development and Issue of revised plans.
7.9.2.2 INCIDENT CONTROLLER – Production manager
1. In the absence of Site Controller, during an emergency
assumes charge as Site Controller also and hands over charge
sooner the Site Controller arrives in the site
2. Direct all operations and coordinate with the concerned to
ensure safety of personnel, minimise damage to the plant,
property and environment
3. Direct shutting down of plant and evacuate the people in the
plant and other areas which are likely to the affected by the
emergency, if required
4. Ensure all key personnel’s help is called in
5. Keep in constant touch with site controller for advice on further
appropriate action
6. Provide advice and information to the Fire, Security Officer and
outside fire brigade through the Fire & security Officer
7. Ensure that all non-essential workers are evacuated to the
appropriate assembly points
8. Report all the significant developments of the Liaison Officer
12. During non-emergency time, he would ensure that safety
related procedures. Personal protective equipment are
maintained up to date and in usable condition.
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7.9.2.3 EMERGENCY CONTROLLER – Manager Logistics
1. On hearing about an Emergency, reach ECC or the location as
suggested by Site Controller, duly protecting themselves.
2. Report to Site Controller. Handles police and Press, if needed
3. Ensure that all non- essential workers in the affected area are
evacuated to assembly points in consultation with the Incident
Controller
4. Any important information as required to the senior officers will
be provided
5. Keep liaison with other co-ordinators to meet the requirements of
services such as materials, security management, transportation,
medical facilities etc. as required during emergency
6. He is in constant touch with the site controller and feed him
correct information of the situation.
7. Ensure that casualities receive adequate attention at medical
centre and arrange required additional help and inform relatives
of the injured
8. Engage suitable staff to act as runners or messengers who are
listed in the essential workers list between him and the Incident
Controller, if the telephone and other system of communication
fail due to any reason
9. Keep in constant touch with happenings at the emergency site
and offer suggestions to the incident Controller
7.9.2.4 Fire and security Officer
On hearing the Emergency alarm, he will reach Spot.
1. Take control over the fireman, trained plant personnel and
security staff and arrange required fire fighting facilities to the
emergency site. He will call fire brigade from Hyderabad, if
required.
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2. Maintain communication with the Site Controller, Incident
Controller and Communication Officer.
3. Arrange to control the traffic at the gate and the incident area
4. Direct the security staff to the incident site to take part in the
emergency operations under his guidance and supervision
5. Evacuate the people in the plant or in the nearby areas as
advised by the Site Controller after arranging the transport
through Liaison Officer
6. Allow only those people who are associated with handling
emergency
7. Maintain law and order in the area; if necessary seek the help of
Police.
7.9.2.5 Safety Officer (Additional responsibility given to Personnel
Reports to Site Controller
On hearing the emergency alarm, he will proceed to this site
He will..
1. Make sure that all safety appliances are made available to the
emergency team.
2. Participate in rescue operations
3. Co-ordinate to transfer the injured persons to medical centre
and arrange for first aid
4. Keep in contact with the Incident Controller and inform the
condition of injured
5. He would train Employees regarding their role during
emergency, emergency facilities.
7.9.2.6 Engineer-In-charge and Electrician: (Maintenance
manager)
They will report to the Incident Controller at the incident site and close
down the services as directed by the Incident Controller
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1. For isolating power supply wherever required including
ventilation system
2. Ensure water supply and functioning of telephones
7.9.2.7 Shit –in- Charge
1. He will act as Site controller. The moment he receives the
information about the emergency and co-ordinate all other
agencies through telephone
2. He will arrange for shutdown of the Process/Plant, if needed
3. He will rtake all preventive measures to stop spread of fire by
closing all the valves carrying inflammable materials and
arrange for evacuation
4. He will effectively utilize the Fire fighting devices to output the
fire till the arrival of the fire brigade, if needed
5. After the arrival of Plant Emergency Team, he will hand over the
charge to the Site Controller and help the team
7.9.2.8 Chemist
He alerts Shift-In-Charge in case of emergency.Takes remedial action
within his purview. Reports to Shift- In- Charge and assist him
i) Plant Operator
1. He alerts the Shift-In-Charge in case of emergency and he
alerts his Co-operators
2. He will assess the situation, takes remedial action within his
purview
ii) Informer
1. he alerts everybody by shouting about emergency
7.9.3 Other Essentials of Emergency Plan
1. Personnel For-
Water pump operation, DG Sets operation, Boiler operation, Fire
personnel, Electrician, Vehicle Drivers
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2. Emergency Control Centre
It is located where Site Controller and others concerned assemble and
conduct operations in emergency. The facilities like P & T Telephones
and safety Appliances, Tools are available readily.
The Emergency Control Centre has been located at a place free from
the effects of hazards in the plant
3. Emergency Warning/ Alarm/ Emergency Communication
4. Familiarization of OSEP to all essential personnel in the Plant is
made
Mock drills are to be conducted periodically to assess the awareness
and familiarity of sequences of OSEP of the essential persons. The
suggestions of the personnel to improve the effectiveness of OSEP are
to be considered and OSEP is being reviewed for further
improvements and effectiveness.
The provision for alerting the personnel in the plant in case of
emergency has been made by ringing bell manually. In addition
messengers are available to communicate the warning to all the
persons in the plant.
7.10 RISK CONTROL PROCEDURES:
7.10.1 HAZARD COMMUNICATION PROGRAM
The department head or his/her designee is responsible for
compliance with the provisions of the hazard communication
program, systematic risk identification and control measures with
the help from EHS department. Training program for all
operators/executives on operational/equipment risk control
measures includes preventing flammable atmospheres by
engineering controls. Specific responsibilities include the periodic
review of department operations that use or store and handle
hazardous chemicals to ensure that
� Containers are properly labelled
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� Appropriate signs have been posted
� Material safety Data sheets are available
� Chemical safety training has been provided and an inventory of
hazardous chemicals is maintained.
� Proper preventive measures on electrostatic hazards
� Follow good CGMP and dispensing practices.
� Regular inspection and checking to assure risk control (proper
earthling, functioning of safety interlocks, bonding,
transferring in closed system and no spillages) The EHS
Department will coordinate the implementation of the hazard
communication program.
Chemical manufacturers, importers, or distributors are required to
ensure that each container for hazardous chemicals is labeled with
hazardous warning signs, and the name and address of the
chemical manufacturer, importer or other responsible party. The
individual Departments will ensure that chemicals they receive are
labeled with the identity of the hazardous chemical(s) and
appropriate hazardous warning signs, and the name and address of
the chemical manufacturer, importer or other responsible party.
The user shall ensure that the indented chemicals are received
along with the MSDS from the supplier with the help of Supply
Chain Management (SCM) /Purchase.
• All employees who work in areas where there are hazardous
chemicals will receive chemical safety training at the time of
initial employment and documented
• chemical safety training includes the following essential
information:
• Location of hazardous materials in the work place
• Location and availability of material safety data sheets
• Acute and Chronic effects of chemicals
• Safe handling procedures
• Personal protective equipment’s (PPE)
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• Emergency procedures and how to obtain First Aid.
• Spill clean – up and Waste disposal
7.10.2 Detailed Action Plan to mitigate in case of Emergency:
• When the emergency observed the operator/supervisor to
operate manual call point in case of emergency.
• Operator will move to safe distance and also ask nearby
personnel to move to safe place (Assembly point).
• Security will inform to site controller, incident controller & EHS
head.
• Incident controller (concern area head) will rush to the site and
ask ERT members to approach the site with SCBA and inform to
site controller to declare emergency.
• Site controller will inform to security to declare emergency by
hooting emergency siren based on the report received from
incident controller.
• Security will declare emergency based on site controller
instruction and request to evacuate by using a megaphone.
Wind direction also to be informed.
• Meanwhile incident controller will initiate the control procedure
with the help of ERT members (Spill control procedure/operating
fire hydrant system etc.).
• Help from maintenance dept. will be sought if necessary to cut
off power supply/ close the valves to receivers and any
temporary power connections to emergency appliances.
• Site controller will assess the situation from Emergency control
centre and will send ambulance, spill content/fire fighting
equipments and required PPE.
• Care shall be taken that no vehicle shall be allowed in the close
vicinity of the spill/fire (about 50 meters) and movements shall
be from upwind directions only.
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• Incident controller will ask explosive meter to monitor the area
with the help of ERT member/Safety in-charge.
• Incident controller will inform site controller of requirement of
outside help, if any.
• When the situation is under control incident controller will
inform to site controller.
• Incident controller will ensure that,
o The spilled material, spill control materials and other
wastes are disposed off properly.
o Area washed with water thoroughly
o PPE are washed and kept at their respective locations.
o Spill control materials, fire extinguishers are replenished.
o Evidence recorded and maintained for further
investigations.
• Site controller will ask security to give “all clear” siren and
employees will be allowed to go to their respective work places, if
head count is complete.
• A meeting will be called in conference room with all block in-
charges, maintenance engineers, ERT members, security officer,
incident controller and site controller.
• The incident will be discussed in detailed and minutes will be
maintained for future improvements.
• A detail report will be prepared by site controller and incident
controller and submitted for management review.
7.10.3 Control Measures:
• A current inventory of all chemicals and hazardous chemicals
present in the workplace is maintained, the inventory of
flammable materials are maintained in less quantities.
• Lightening protection provided at diesel storage tanks area.
• Flammable solvents are handling at FLP areas.
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• Flammable solvents are transferring by using metallic hand
operated pumps into metal containers. Proper earthing and
bonding provided for solvent handling equipments.
• Equipments only wiping with lint free cloth instead of cleaning with
flammable solvents.
• Dispensing carried out at FLP zone.
• Spill control kits are provided at flammable solvents handling
areas. Spill control procedures are also displayed to control risk.
• Explosion flaps provided for Air tray dryers to prevent explosion.
• Addressable fire detection system provided.
• Fire hydrant system provided with diesel driven backup.
7.10.4 HANDLING SPILLS
The risk assessment includes the following factors:
• The nature of the spilled chemical (high/low hazard material)
• The quantity spilled (large/small amounts)
• The location of the spill (difficult access, public site / bonded area)
When evaluating risks associated with chemical spills, the
following points need to be considered:
Is special training required to handle the situation?
Is special equipment required to clean up the spill? (i.e. Self-
Contained Breathing Apparatus (SCBA), Personal Protective
Equipment (PPE etc.)
Are special procedures required to clean up the spill? e.g. pumps,
hoses etc.
Where the response is HIGH to any of the above factors then the
spill must be considered as HIGH RISK.
7.10.4.1 SPILL CONTROLS (RISK CONTROLS):
Engineering – Handling in closed system. Bund provided for storage
area. Includes redesigning the work area, fixing rollover bund
guard(s) or maintenance.
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Administrative – standard operating procedure, supervision, training
and signage.
Personal protective equipment – Includes PAPR/3M half face masks,
safety shoes, goggles, safety glasses and gloves.
• Spill kits available for use where assessed as required. The
contents of the spill kit should be relevant to the area and the
potential spill, this may include such things as;
• Soda Ash available for spills of corrosive liquids.
• Sand to absorb spilt liquids
• Absorbent pillows or booms to contain larger liquid spills and
prevent spills entering drains
• Heavy duty HDPE containers (with a lid) to contain hazardous
material prior to disposal.
• Appropriate personal protective clothing (such as chemical
resistant gloves, safety glasses)
• Spill kits are clearly labelled and located in an easily accessible
position for all staff.
7.10.4.2 SPILLS HANDLING PROCEDURE:
• If spill involves personal injury, remove clothing, flush with water
for 15 minutes.
• Alert people in the immediate area of spill.
• Wear protective equipment, including safety goggles, gloves
while going near the spillage.
• Avoid breathing vapors from spills.
• If spilled material is flammable, turn off ignitions and heat
sources.
• Confine spill to small area by creating a bund with soda ash and
sand.
• Absorb with soda ash, dry sand or adsorbent. Collect the residue,
place it in the empty container for disposal. Dispose as chemical
waste.
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• Mop the spill area with water.
7.11 EVACUATION OF PERSONNEL:
On hearing the emergency siren all employees of the factory shall
proceed to assembly point as directed by their department heads.
Head count supervisor will take the head count at assembly point
and report the same to Site controller. During emergencies the
knowledge of exact direction of wind helps the plant personnel to
decide on the escape route to be taken for safe evacuation of
personnel and also the safe assembly points and emergency
operations center. It is therefore necessary that the personnel get
an idea of the direction of the wind by seeing the windsocks
provided at the following.
S. No. Location
1. Top of the new Production Block
7.12 INFORMATION TO RELATIVES OF INJURED
The relatives of injured will be informed by emergency coordinator
(security/transport). The employees residential address file is
available at emergency control centre and also in the residence of
emergency coordinator (security/transport). The communication to
the relatives of injured will be passed on through telecom or by a
messenger with car. The clear address of the injured person (Local
residential address/address of hospital if hospitalized) will be
communicated to the relatives.
7.13 INFORMATION TO LOCAL AUTHORITIES
In case of onsite emergency, the Dy. Chief inspector of factories
and inspector of factories will be informed immediately. The
information will be passed on over telecom, telegram or through a
messenger deputed by Emergency Controller.
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After consulting Dy. Chief Inspector of factories and inspector of
factories, the information will be sent to Chief inspector of factories
also. The company will implement the advice of local authorities in
improving the safety in dealing with the event.
State Pollution Control Board authorities will be informed in case of
accidents like toxic gas release, spillage of hazardous chemicals.
7.14 INFORMATION TO DISTRICT AUTHORITIES
The Emergency controller/site controller/Head HR on advice of
Emergency controller is authorized to inform the police. The
inspector of Police Jeedimetla will be informed for the control of law
and order situation at the Plant or in vicinity or at hospital where
injured are under treatment.
Police department will be requested for protecting the lives of
employees and property of the company, evacuation of personnel
outside the Plant. District Collector, Dist. Medical Officer and
Superintendent of Police, Medchal district will be informed by Site
controller if required.
7.15 MOCKDRILL
Mock Drills would be organized once in six months to evaluate the
preparedness and functioning of OSEP. It is also planned to
undertake few informed and non formed mock drills (or rehearsals)
for meeting emergencies. Such rehearsals would be carefully
analyzed and shortcomings would be identified and necessary
corrections would be taken up. Site controller is responsible for
planning and execution and evaluation of mock drills. Also
information would be given to statutory authorities. It is proposed to
at-least conduct two mock drills in a year and over a period of time
all the sections in all the shifts would be covered. When truck drivers
carrying product are in the plant, they also would be trained
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regarding transportation emergencies and how to react to minimize
the damage or effect on people.
7.16 REVIEW OF ONSITE EMERGENCY PLAN
1. Onsite Emergency Plan would be reviewed whenever there is a
change in product, or product route of manufacture, or addition
of new equipment or change in Site Controller.
2. Site Controller is responsible for such update and making
available latest copy or Onsite Emergency Plan to all concerned
in the organization as will as to the Statutory Authorities.
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