XYZ/EHS/OEP/01

Address Of Your Company

ON SITE EMERGENCY PLAN

Month & Year
REVISION -I

Prepared By

Checked By

Approved By

Safety Officer
[Names & Signature]

Safety Manager

Unit Head

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INDEX
CHAPTER NO. TOPIC PAGE NO.

1 2

PREFACE PREAMBLE
1 Emergency 2 Nature of Emergency 3 Process Description 4 Identification of Hazardous Area 5 Objectives of the Plan 6 Emergency Control Center 7 Assembly Points 8 Codification of Sirens 9 Training & Education Training & Education 10 Mock drill 11 Updating the Plan 5 5 6 6 7 7 8 8 9 9 9

4 5 -9

10

3 4

EMERGENCY ORGANISATION KEY PERSONNEL AND THEIR RESPONSIBILITIES

1 2 3 4 5 6 7 Site Controller Incident Controller Personnel / Administrative Manger Security Officer Departmental Heads First Aid team Factory Fire Squad Personnel 11 12 13 13 14 14 15

10 11 - 15

5 6.

EMERGENCY ACTION PLAN LIST OF ANNEXURES

16-22 23-49

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LIST OF ANNEXURES
A. B. C. D. E. F. G. H. I J K L Brief description of the manufacturing process Telephone numbers of Police, Fire Brigade, Hospitals & other outside Emergency Services Telephone numbers & addresses of Key Personnel Telephone numbers of MARG members. List of Fire and Rescue Squad Members Information on Fire hydrant System List of fire Extinguisher. List of Personnel Protective Equipment. First aid medical facilities. List of Some hazardous Chemical and action. Scenario Based Emergency action. Emergency organization Chart

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CHAPTER 1 PREFACE
1.1 The enclosed On-site Emergency Plan is made for the Bulk drug manufacturing
plant of M/s XYZ Ltd. Plot No: XYZ, MIDC, ___________ 1.2 The plant has a manufacturing facility to produce Bulk Drug viz..

1.3

The plant is designed and equipped to handle hazardous chemical and to carry out various processes and operations on these chemicals. The plant is provided with Fire Hydrant system, Fire extinguishers and Scrubber system. In addition to this adequate types and number of Personal Protective Equipement, First Aid Boxes, Eye washers, Ventilation system has been provided.

1.4

Considering the types of operations carried out in the plant and the nature, extent of hazards existing, the management of M/s XYZ LTD thought it necessary to have some system of tackling an emergency.

1.5

The formulation of this document is an outcome of the above thought process.

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CHAPTER 2 PREAMBLE
In spite of various preventive and precautionary measures taken in the plant, the possibility of a mishap cannot be totally ruled out. Hence, the need to prepare a Contingency Plan for dealing with incidences which may still occur and are likely to affect LIFE and / or PROPERTY, both within the plant and in the immediate neighborhood. Such an emergency could be the result of malfunction of the Plant & Equipment or nonobservance of operating instructions. It could, at times, be the consequence of acts outside the control of plant management like severe storm, earthquake, flooding, or deliberate acts of arson or sabotage.

A Major Emergency in the plant is one that may cause serious injury or loss of life and damage to the property. This On Site Emergency Plan (OEP) explains the code of conduct of all personnel in the plant along with the actions to be carried out in case of an Emergency. This plan gives the guidelines for employees, contractors, transporters, etc. It not only defines responsibilities but also informs about prompt rescue operations, evacuations, rehabilitation, co-ordination and communication. 1. EMERGENCY: An Emergency is a situation, which may lead to or cause large-scale damage or destruction of life, property or environment within or out side the Factory. Such an unexpected situation may be too difficult to handle within the plant. 2. NATURE OF EMERGENCY: The emergency specified in the OEP refers to occurrence of one or more of the following events: for the normal work force

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a. b. c. d. 3.

Fire/Explosion. Major accident such as structural or building collapse, overturning of road tanker containing flammable substances. Natural calamities like storm, flood, earthquake, etc., Sabotage act of terrorism, civil commotion, air raid etc.

PROCESS DESCRIPTION: A brief description of the Manufacturing Process is given in Annexure A.

4.

IDENTIFICATION OF HAZARDOUS AREAS:

HAZARD Explosion

AREA

PROBABLE CAUSE OF THE ACCIDENT

Boilers / Transformers Malfunctioning of the / Receivers for the Air Safety Valve compressors.

Flammable Petroleum Product Storage Tank / Drum Storage area

Fire

External fire causing pressure built up in the tanks / barrels

H.S.D. / FO Storage Flammable vapor / air Area mixture and source of ignition. Flammable Petroleum Formation on pool in the Product Storage dyke wall and source of Tank / Drum Storage ignition. Shed /Production Area External fire Built up of internal pressure Failure of the top cover Tank on Fire

Spillage

Acid / Alkali Storage Spillage of Acid / Alkali due Area to rupture of the pipe line, collapse of the storage tank

.
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5.

OBJECTIVES OF THE PLAN: a) b) c) d) e) f) g) To control the emergency, localise it and if possible eliminate it. To avoid confusion, panic and to handle the emergency with clear cut actions. To minimize loss of life and property to the plant as well as to the neighbourhood. To make head count and carry out rescue operations. To treat the injured persons. To preserve records and to take steps to prevent recurrence. To restore normalcy.

6.

EMERGENCY CONTROL CENTRE: For the purpose of handling emergency, the following Emergency Control Centres has been identified. During normal working hours - The Administrative Office During other times - The Security Office.

All communications to and from will originate at this CONTROL CENTRE. The Emergency Control Center will have the following: a) b) A copy of ON-SITE EMERGENCY PLAN. List of important telephone numbers such as Police, Fire Brigade, Hospitals, and other outside Emergency Services, etc. (Refer Annexure B). c) d) e) f) g) h) i) 7. List of key Personnel with addresses and telephone numbers. (Refer Annexure C). List of Fire and Rescue Squad Members (Refer Annexure E). Plant layout indicating storage of hazardous materials List Fire Extinguisher. (Refer Annexure G). Fire Fighting System (layout of Fire Hydrants) List of Personal Protective Equipment (Refer Annexure H) First Aid box.

ASSEMBLY POINTS

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In case of an EMERGENCY the employees should assemble near the defined Assembly Points, as indicated below: -

Fire Fighters - Area near Security Gate. First Aiders - Area near Security Gate. Others - Area near Security Gate.

Wind direction to be determined by the WIND SOCKS installed on top of the Engineering Building. THE EMPLOYEES SHOULD RUN PERPENDICULAR TO THE WIND DIRECTION AND NOT AGAINST / ALONG THE WIND DIRECTION. 8. CODIFICATION OF SIRENS Sr. 1. 2. SIRENS 30 SECOND CONTINUOUS 1 MINUTE CONTINOUS INDICATES ON SITE EMERGENCY (ALERT) EMERGENCY CONTROLLED (ALL CLEAR) NOTE: 1) 2) 3) 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. AUTHORITY INCIDENT CONTROLLER SITE CONTROLLER

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9.

TRAINING AND EDUCATION:

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Experience with on site emergency planning has proved the need of training and rehearsal. Major emergency procedure should be laid down clearly and convincingly to everyone on site particularly Key Personnel and Essential workers. It is obvious that in house or outdoor training is essential. The duties and responsibilities of each person and the emergency procedure to be followed by him should be very clear. a. Seminar/refresher guidance On Site Emergency Plan. b. Emergency instruction Booklet. Seminar: Seminar is conducted in house/. Site controller will explain the plan to all associated concerned employees. Expert from outside explain the plan to all associated concerned employees. Expert from also may be invited to impart training. Emergency instruction Booklet: Emergency instruction Booklet contains all detailed emergency duties. The booklet contains Emergency duties, Reporting relationship. Thus everyone is conspicuous about his role in the Emergency Plan.

10.

MOCK REHEARSAL:
Inform all the employees about mock drill. Fix the date for mock drill. Observers will not be involved in the exercise. They will monitor the Mock drill. Emergency Siren / alarm will be raised. After hearing the Siren / alarm, Emergency procedure will be followed as mentioned in the OEP. Observer will note down the activities with respect to the time.

11.

UPDATING THE PLAN:

As and when required the On Site Emergency Management plan will be updated. After each drill the plan will be thoroughly received to take account of shortcoming and accordingly plan will be updated.

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CHAPTER - 3 EMERGENCY ORGANISATION

Responsibility will be automatically delegated in absence of concern person/s in following manner. SITE CONTROLLER: xyz INCIDENT CONTROLLER: DUTY OFFICER ON SUNDAYS/HOLIDAYS ADVISORY COMMITTEE: ALL HODs, Sachin K. Thorat COMMUNICATION COMMITTEE: P&A DEPARTMENTS

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CHAPTER - 4 KEY PERSONNEL & THEIR RESPONSIBILITIES

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Key Personnels Responsibility during normal working hours :1. Site Controller: He will retain overall responsibility for the factory and its personnel. As soon as he is informed of the emergency he shall proceed to the control room and meet the P&A. Manager. His duties shall be: i) Assess the magnitude of the situation and decide if staff needs to be evacuated from their assembly points. ii) iii) Exercise direct operational control over areas other than those affected. Maintain a continuous review of possible development and assess in consultation with Incident Controller and other Key personnel as to whether shutting down of the plant or any section of the plant and evacuation of persons is required. iv) Liaison with Senior Officials of Police, Fire Brigade, Directorate of Industrial Safety, provide advice on possible effects on areas outside the factory premises. v) vi) Control rehabilitation of affected areas on discontinuation of emergency. Issue authorised statements to news media, and ensure that evidence is preserved for inquiries to be conducted by statutory authorities.

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2.

Incident Controller: On hearing of an emergency siren he will rush to the scene of the occurrence and take overall charge and report to Site Controller. On arrival he will assess the scale of emergency and decide if major emergency exists or is likely and inform the Communication Officer accordingly. (1) Direct all operations within the affected areas with the priorities for safety of personnel minimise damage to the plant, property and minimise loss of materials. (2) Pending arrival of Site Controller, assume the duties of his post and, in particular. (3) (a) Direct the shutting down and evacuation of plant and areas likely to be adversely affected by the emergency. (b) (4) Ensure that all Key personnel and outside help are called in.

Provide advice and information to the Fire squad & Security Officer and the local fire service as and when they arrive.

(5)

Ensure that all non-essential workers/staff of the areas affected are evacuated to the appropriate assembly points, and the areas are searched for casualties.

(6)

In the event of failure of electric supply and internal telephones, set up communication point and establish contact with Emergency Control Centre.

(7)

Report on all significant developments to the P. & A manager.

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(8)

Have regard to the need for preservation of evidence so as to facilitate any inquiry into the causes and circumstances, which caused or escalated the emergency.

3.

Human Resources Manager: He will also work as liaison Officer and will be stationed at the Main Entrance (Security Office near Main Gate) during the emergency. He will under the direction of the site Controller handle police, press and other inquiries, receive reports from roll-call leaders from assembly points and pass on the absentee information to the Incident Controller. His responsibilities shall include (1) (2) (3) (4) (5) To ensure that casualties receive adequate attention, to arrange additional help if required and information relatives. To control traffic movements into the factory and ensuring that alternative transport is available when need arises. When emergency is prolonged, arrange for the relief of personnel and organise refreshments / catering facility. From information received, advise the Site Controller of the situation, recommending (if necessary) evacuation of staff from assembly points. Recruit suitable staff to act as runners between the Incident Controller and himself if the telephone and other system of communication fails due to whatsoever reasons. (6) (7) Maintain prior agreed inventory in the control centre. In case of prolonged emergency involving risk to outside areas by windblown materials, contact local Meteorological Office to receive early notification of changes in weather conditions.

4.

Security Officer: On hearing alarm advise fire squad and security staff in the factory of the incident zone and cancel the alarm. He will also announce through telephone or messengers to the HR Manager, Incident Controller and Site Controller that incident has occurred in such and such zone. He will open the gates nearest to the incident and stand by to direct the emergency service.

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If told of a large escape of gas he shall inform the Incident Controller by telephone and stand-by the telephone to receive further messages. On hearing the emergency alarm, he will immediately contact Site Controller and on his advice call the local fire brigade. In case fire is discovered but no alarm is sounding he shall receive information about location from the person discovering the fire and thereafter immediately consult the Site Incident Controller and make announcement on telephone telling the staff location of the incident and to evacuate to their assembly points. He will continue to operate the switchboard advising the calls connected with the incident to the Communications Officer. 5. Departmental Heads: The Departmental head wherein the incident has taken place will report to Incident Controller and provide assistance as required. They will decide which members of their staff they require at the scene. 6. First-aid Teams: The Personnel Manager shall keep in security the roll call lists for the fire and first-aid teams on duty. Each Departmental Head for his shift-team appoints roll call leaders and first aiders. Roll call leaders shall check their rolls as members of the services report for emergency duty. Names of any unaccounted for absentees will be informed to the Security Officer. Members of first-aid Teams will report to the Incident Controller on hearing of the alarm in day time. The Emergency vehicle driver, if safe to do so, shall collect the emergency vehicle and park nearest to the scene of the incident. First aider shall inform the incident controller that the Emergency Vehicle is leaving the site, giving the name of the patient and destination i.e. hospital or doctors room and request the Incident Controller to inform the destination (hospital, etc.) advising them about the casualties reaching there.

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7. Factory Fire Squad Personnel: The duty Fire fighting Squad under the command of the Security Officer shall be responsible for fire fighting and rescue. On hearing the alarm, they shall proceed to the place of incident. The men at security gate shall find out the location of the emergency and proceed to the site of the occurrence. At the incident scene, a team members detailed for this purpose will check squad members against roll-call sheet. At the site, all the squad members will respond to the advice and information given by the Incident Controller On arrival of the local fire brigade, they will also assist in fire-fighting work with the advice of the Incident Controller.

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CHAPTER - 5 EMERGENCY ACTION PLAN

ANY ONE NOTICING EMERGENCY SITUATION LIKE FIRE, EXPLOSION, TOXIC GAS LEAKAGE ETC. MUST DOs Attract the nearby person/employee by shouting FIRE FIRE FIRE. Seek help from the persons working nearby. Try to control the incident at its initial stage with available means/sources quickly. Inform Shift In-charge / Duty Officer (In Night Shift ) about the Incident.

DONTs Do not be panicky. Do not run Walk fast.

INCIDENT CONTROLLER MUST DOs A. IF FIRE / OTHER INCIDENTS ARE CONTROLLABLE Approach the emergency site immediately taking note of wind direction. Assess the situation. Inform Security Officer, Tell NAME, TYPE OF INCIDENT, ACTION TAKEN, Take lead in controlling emergency until such time concerned Section Manager

HELP NEEDED and Order Security Officer/Guard to inform all KEY persons. takes over the charge.

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DONTS Do not be panicky. Do not lose temperament.

B. IF FIRE/OTHR INCIDENTS ARE NOT CONTROLLABLE In Addition to Above (A) Order to blow emergency `ALERT Siren (30 second continuous). Organize Fire fighting / rescue team members to control the Incident. Take stock of situation if required shut down the plant / process in affected area. Call Fire Brigade if situation demands. Evacuate affected area. Organize head count of the plant. Act as INCIDENT CONTROLLER till such time senior person takes charges as indicated in Emergency organisation NOTE: 1) Messenger will wait until such time Security Officer arrives. 2) Also inform Telephone Operator. SECURITY OFFICER / GUARD DOs Do not allow any vehicle to come inside the factory. Do not entertain any outside call except for emergency purpose. Do not allow visitors to move around. Inform all key persons about location and type of emergency. Follow this sequence Inform concerned HOD/Section Head, Main Site Controller, Main Incident Controller & Safety Officer and other KEY persons. Inform Main Site Controller about Government visitors, if any. DONTs Do not entertain any outside call except for emergency purpose. Do not allow visitor to move around, from reception.

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SECURITY GUARD DOs Immediately report at Security Gate in shortest possible time. Follow instructions of Officer In-charge. Assist in controlling emergency. Assist in controlling contractors, vehicle movement and mob. Assist in cordoning off the area. Take note of wind direction while approaching emergency site. Render all possible help for controlling overall situation.

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

EMERGENCY VEHICLE DRIVER DOs Immediately start vehicle and reach rescue squad assembly point (near security gate). Rescue squad members to emergency site. Take vehicle near to emergency site as directed. Take note of wind direction. Reverse the emergency vehicle for quick transports of injured, if any. Keep vehicle engine running. Always be on Drivers seat of the vehicle. Take the injured to the hospital as directed. DONTs Do not leave the vehicle. Do not take the vehicle very near to the site.

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INCIDENT CONTROLLER DOs Approach emergency site as early as possible taking note of wind direction. Take stock of situation. Interact with all concerned departments as the situation demands. Keep Main Site Controller informed about the latest emergency situation on continuous basis. SITE CONTROLLER DOs Will approach emergency site immediately / Assess the situation. Consult Incident Controller. Consult advising Committee Members. Instruct Main Incident Controller. Communicate to higher ups and Govt. authorities, if required. Decide upon need for evacuation and blow `Disaster Siren. After getting satisfied with the situation, give instruction to blow ALL CLEAR Siren.

DONTs Do not instruct to blow ALL CLEAR siren unless the situation is fully under control. Dont evacuate the entire plant unless the situation demands.

FIRE FIGHTING SQUAD ON HEARING SIREN DOs Inform fellow employees/Officers. Report to Fire Squad Assembly point.

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Find out emergency location. Approach emergency site immediately.

Take quick action as per the instructions from Incident controller. Bring emergency under control as early as possible.

DONTs

Do not leave process/equipment 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 DOs Report to assembly point near Gate. Get in touch with security about location and type of emergency. Approach emergency site quickly with Breathing Apparatus set and First Aid box. Get in touch with incident controller. Follow instructions of Incident controller. Render first aid to the injured, hospitalize, if required. Accompany him to hospital and assist Doctor / Nurse. Search for missing person in that area, if required. Help in head count. ALL GENERAL EMPLOYEES EXCEPT THOSE WHO ARE IN EMERGENCY ORGANIZATION ON HEARING SIREN DOs Be alert and be available if required. Wait for further instructions. Bring down the process/plant/equipment in SAFE CONDITION in case of DISASTER siren as per instructions from Incident Controller. Approach respective safe assembling points route as taking note of wind direction.

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Help in taking roll call. After hearing ALL CLEAR, go back to the departments. Start the work again after setting instruction from Incident controller.

DONTs Do not be panicky. Do not run. Do not approach emergency site unless asked for. Do not engage telephone except for emergency purpose. Keep lines free. TECHNICAL TEAM: ENGINEERING DEPARTMENT / ENVIRONMNET, SAFETY AND HEALTH DEPARTMENT ON HEARING SIREN DOs Be available in Engineering Department at respective location for any help. Approach emergency site with required with tools and equipments and should work on instructions of Incident controlle. Help Incident Controller to provide technical assistance. Isolate lines, process equipments, if required by Incident Controller. Provide emergency equipments like Fire Extinguisher, Hoses, etc., if asked by Incident Controller. Provide stop gap arrangements as per the requirement of Incident Controller. Carry out electrical isolation of area as per instructions from Incident Controller. ADVISORY COMMITTEE (ALL DEPARTMENT HEADS) DOs Approach emergency site as early as possible. Render advise to Main Incident Controller and Main Site Controller to control emergency. COMMUNICATION COMMITTEE (P&A)

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DOs Consult Main Site Controller Give necessary instructions to security / Telephone Operator. Give instruction to Security to control traffic / crowd. Look after injured, communicate with the family members, if situation demands. Arrange transportation, if required. DONTs Do not communicate to any one or brief press without permission of Main Site Controller. GENERAL INTRUCTIONS DOS Stop work at height. / Stop all hot works. Stop all vessel entry. Take note of wind direction. On hearing Disaster Siren evacuates as per evacuation route without running and panicky and assembles at respective safe Assembly Points. DONTs Do not use telephone except for emergency purpose. Do not start work at height, vessel entry, hot work unless permit conditions are verified. Do not allow unauthorized person to approach emergency site.

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-------------------ANNEXURE A
BRIEF DESCRIPTION OF THE MANUFACTURING PROCESS
BRIEF MANUFACTURING PROCESS OF ---------------------Stage I: Stage II: Stage III: Stage IV: BRIEF MANUFACTURING PROCESS OF --------------------Stage I: Stege II:

Stage III: BRIEF MANUFACTURING PROCESS OF --------Stage I:

Stage II:

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BRIEF MANUFACTURING PROCESS OF -----------------

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ANNEXURE B
TELEPHONE NUMBERS OF POLICE, FIRE BRIGADE, HOSPITALS, AND OTHER OUTSIDE EMERGENCY SERVICES

POLICE DEPT-

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XYZ/EHS/OEP/01 FIRE BRIGADE

M.S.E.B. OFFICE: -

GRAMPANCHAYAT OFFICE :-

HOSPITALS :-

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ANNEXURE C
TELEPHONE NUMBERS AND ADDRESSESOFKEY PERSONNEL
LIST OF KEY PERSONS

NAME

RESIDENCE TEL. NO.

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ANNEXURE D
MUTUAL AID SCHEME MEMBERS
MUTUAL AID RESPONSE GROUP
NAME COMPANY OFFICE PHONE

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ANNEXURE E
LIST OF FIRE AND RESCUE SQUAD MEMBERS

FIRE FIGHTING SQUAD

FIRST AIDER(RESCUE SQUAD)

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ANNEXURE F
EMERGENCY CONTROL SYSTEM FIRE HYDRANT SYSTEM
An underground Fire Hydrant System has been installed in the plant with rings around all blocks to achieve maximum coverage. Water reservoir of 135m3 (Hydrant tank) + 20 m3 (MIDC Storage tank with feed from the MIDC water supply has been provided at highest point in the plant. Following are the details of the system. a. Water Reservoir- 135+20 m3. b. Type of Hazard- Pharamaceutical, Ordinary Hazard. c. Design Code-TACs Fire Protection Manual. d. Total no. of Fire Hydrant including landing Values, Watermonitor-19 Nos.

e. Automatic Operation-Jockey pump of 10.8 m3/hrs@70Mhead capacity

with pressure switches. f. Stand by arrangement-Diesel Generator with AMF control panel. g. Nos of Hose Boxes-External-18 nos h. Nos of Hoses-36 i. j. Nos of Nozzles-15 mm bore-17 nos. Hydrant flexible rill-6 nos. - 70 M head 38 M /hour flow at 7 kg./cm
3 2

k. Electric Driven main pump

-No 1 l.

One Jockey pump provided of capacity 23 m3 /hr 91 M Head. hydrant pump is kept working.

m. Auto changeover switch operated DG set System ensures that the

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ANNEXURE G
FIRE EXTINGUSHER List of Fire Extinguishers
The company has trained personnel for fire fighting and its intends to improve the fire fighting skills of their employee by conducting training on Fire fighting. There are 44 portable fire extinguishers, the break-up of which is as under: -

Sr.No.
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24

Area

Location

Type DCP DCP DCP FOAM DCP DCP DCP DCP DCP DCP FOAM DCP DCP FOAM DCP CO2 DCP CO2 DCP CO2 CO2 DCP DCP FOAM

Capacity 5 KG 5 KG 5 KG 50 Lit 5 KG 5 KG 5 KG 5 KG 5 KG 5 KG 50 Lit 5 KG 5 KG 50 Lit 5 KG 3.0 KG 5 KG 6.5 KG 10 KG 3.0KG 3.0 KG 5 KG 10 KG 50 Lit

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XYZ/EHS/OEP/01 25 26 27 28 29 30 31 32 33 34 35 DCP CO2 DCP DCP CO2 DCP DCP DCP CO2 CO2 DCP 5 KG 6.5 KG 5 KG 5 KG 3.0 KG 5 KG 5 KG 5 KG 3.0 KG 3.0 KG 5 KG

Sr.No.
36 37 38 39 40 41 42 43 44

Location

Type CO2 DCP DCP DCP DCP CO2 FOAM DCP DCP

Capacity 3.0 KG 5 KG 5 KG 5 KG 5 KG 3.0 KG 9 KG 5 KG 5 KG

Total Fire Extinguisher:

Sr. No 1 2 3 Types of Extinguisher DCP CO2 Foam 06 09 Total Nos. 29

Sand Buckets: 05 Nos

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ANNEXURE H
LIST OF PERSONAL PROTECTION EQUIPMENT
LIST OF PERSONEL PROTECTIVE EQUIPMENTS ITEM Safety Helmet Safety Goggles Safety Shoes PVC Apron Asbestos Gloves Rubber Gloves Eye Wash Fountain Gum Boots Cloth Mask Safety Belt Organic Vapor Mask Self Contained Breathing Apparatus NOS. 100 20 52 05 05 50 05 02 10 04 10 01

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ANNEXURE I
FIRST AID MEDICAL FACILITIES.
The company has provided First AID boxes at security office. Following are the contents of First aid. 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. Tincture iodine. Eye wash solution. Burnol Soframycin (ointment) Sterilized cotton wool. Band-aid. Antiseptic Solution (Dettol) Bandage. Paracetamol tablets. Iodex. Pair of scissor.

The company has got its own transport facilities to take the injured to the hospital. The nearest hospitals are _________________________________

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ANNEXURE J
List of some Hazardous Chemicals and Action
Sr. No Name Boiling points Flash points Explosive limits Lower % VOL 6 Upper TLV in Action to be taken

Methanol

64

11

PPM % VOL 36 200 Use AFFF For extinguishing fire. Use SCBA and Other PPE. Use AFFF For extinguishing fire. Use SCBA and Other PPE Use SCBA and Other PPE Use AFFF For extinguishing fire. Use SCBA and Other PPE Use AFFF For extinguishing fire. Use SCBA and Other PPE Use AFFF For extinguishing fire. Use SCBA and Other PPE Use AFFF For extinguishing fire. Use SCBA and Other

Toluene

110

1.3

6.8

100

3 4

MDC Ethyl Acetate

39.8 77

-4

12 2

23 11.5

50 400

IPA

82

12

12

400

Ethanol

77

13

3.3

19

100 0

n-Hexane

68

-21

1.1

7.5

50

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PPE

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List of some Hazardous Chemicals and Action

Sr No Name Boiling points Flash points Explosive limits Lower % 8 DMF 153 58 VOL 2.2 Upper % VOL 15.2 10 Use AFFF For extinguishing fire. Use SCBA and 9 Acetone 56.5 -20 2.5 12.8 500 Other PPE Use AFFF For extinguishing fire. Use SCBA and 10 THF 66 -14 2 11.8 200 Other PPE Use AFFF For extinguishing fire. Use SCBA and 11 Di-ethyl ether 35 -45 1.9 36 400 Other PPE Use AFFF For extinguishing fire. Use SCBA and 12. TriethylAmine 90 -9 1.2 8 10 Other PPE Use AFFF For extinguishing fire. Use SCBA and 13 Dimethylamine 7.4 -6 2.8 14.4 10 Other PPE Use AFFF For extinguishing fire. Use SCBA and Other PPE TLV in PPM Action to be taken

ANNEXURE K
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SCENARIO BASED EMERGENCY ACTION

Based on the reactions involved during the production process and the raw material involved the possible hazards are indentified. The action for the emergency situation is given.
Product Name

Sr. no 1

Type of Reaction Oximination

Critical raw material Methylene chloride

Possible Hazards Irritating to eyes, skin with burning pain etching and redness. Gastrointestinal irritation with nausea, vomiting and diarrhea, may cause kidney damage. CNS depression, followed by headache, dizziness, drowsiness.

Action Immediately flush with large amount of water; if inhaled remove to fresh air.

Liq. Ammonia

Ammonia vapors are highly irritant and corrosive.

Immediately flush with large amount of water. Use respiratory protection. Immediately flush with large amount of water to any area of contact. Immediately flush with large amount of water to any area of contact. Follow fire action in case of fire.

Hydroxylamine hydrochloride

Harmful if swallowed, inhaled or absorbed through skin, causes burn to any area of contact.

Triethylamine

Corrosive and irritating to the eyes, skin, all living tissues and respiratory tract.

Methanol

Flammable liquid, causes severe eye

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irritation, may cause blindness if swallowed; may cause skin irritation, CNS depression, and liver, kidney damage. 2 Silylation 2-Methoxy propane Flammable liquid and vapor may cause flash fire, harmful if swallowed, inhaled or absorbed through skin, of contact. Hexamethyldisilazane Highly flammable, corrosive and harmful to any area of contact.

Immediately flush with large amount of water to any area of contact.

Follow Fire action in case of Fire. Immediately flush with large amount of water to any area of

causes burn to any area body contact.

Follow Fire action in case of Fire. Immediately flush with large amount of water.

Pyridine hydrobromide Toluene

Irritant to eyes and skin. Keep away from heat and ignition source; harmful if swallowed, inhaled or absorbed through skin; causes burns to any area of contact.

Immediately flush with large amount of water. Follow Fire action in case of Fire. Immediately flush with large amount of water.

Sodium carbonate

May cause eye burn; irritation to skin and respiratory tract; harmful if swallowed

Immediately flush with large amount of water.

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Methylation

Methyl iodide

or inhaled. Potentially fatal if inhaled; harmful if swallowed, respiratory tract irritation, skin irritation, eyes irritation and CNS depression.

If breathing is difficult oxygen should be administered by qualified personal and wash with water if contact with skin and eyes. Immediately flush with large amount of water.

Dimethylsulfoxide

Corrosive and irritating to the eyes and skin, all living tissues and respiratory tract.

Dimethylamine (40%)

Extremely flammable liquid and vapor may cause flash fire, harmful if swallowed, inhaled or absorbed through skin, causes burn to any area of contact.

Follow Fire action in case of Fire. Immediately flush with large amount of water.

Potassium hydroxide

May causes burn to the eyes, skin, respiratory and gastrointestinal tract. Harmful if swallowed, may cause irritation.

Immediately flush with large amount of water. If swallowed, induce vomiting immediately after giving two glass of water. Immediately flush with large amount of water.

Deprotection

Sodium bisulfite

Formic acid

Corrosive and

Immediately flush

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irritating to the eyes, skin, all living tissues and respiratory tract. Ethanol Sodium Hydroxide Flammable liquid May causes burn to the eyes, skin, respiratory and gastrointestinal tract.
2. Product Name

with large amount of water. Follow fire action in case of fire. Immediately flush with large amount of water.

Sr. no 1

Type of

Critical raw

Possible Hazards Flammable liquid and vapor; harmful if swallowed or inhaled; affects CNS; causes irritation to skin, eyes and respiratory tract.

Action Follow Fire action in case of Fire. Remove to fresh air; If not breathing give artificial respiration; if it is difficult give oxygen. Give large amount of water to drink. Immediately flush with water. Immediately flush with large amount of water to any area of contact. Follow Fire action in case of Fire. Immediately flush with large amount of water.

Reaction material Cycloalkylation 1,3dibromopropane

DMSO

Corrosive and irritating to the eyes and skin, all living tissues and respiratory tract.

Toluene

Keep away from heat and ignition source; harmful if swallowed, inhaled or absorbed through skin; causes burns to any area of contact.

Methylene chloride

Irritating to eyes, skin with burning pain

Immediately flush with large amount of water; if

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etching and redness. Gastrointestinal irritation with nausea, vomiting and diarrhea, may cause kidney damage. CNS depression, followed by headache, dizziness, drowsiness. 4-Chloro phenylacetonitrile Hazardous in case of skin contact, eye contact or inhalation, severe exposure can result in death. 2 Tandem Grignard reduction Bromomethyl propane Flammable liquid and vapor; harmful if swallowed or inhaled; affects CNS; causes irritation to skin, eyes and respiratory tract. Magnesium metal Highly inflammable, and harmful if swallowed or inhaled. Irritating to eyes, nose, throat, skin and CNS; over exposure to the vapor may cause headache, drowsiness. Isopropyl alcohol Flammable liquid; harmful if swallowed or inhaled. Irritating to eyes, nose, throat, skin

inhaled remove to fresh air.

Immediately flush with plenty of water. If inhaled remove to fresh air. If not breathing give artificial respiration. Follow Fire action in case of Fire. Remove to fresh air; If not breathing give artificial respiration; if it is difficult give oxygen. Give large amount of water to drink. Follow fire action in case of fire. Immediately flush with large amount of water.

Follow fire action in case of fire. Immediately flush with large amount of water.

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and CNS; over exposure to the vapor may cause headache, drowsiness. Tetrahydrofuran Keep away from heat and ignition source; harmful if swallowed, inhaled or absorbed through skin; causes burns to any area of contact. Ethyl acetate Flammable liquid and vapor. Harmful if swallowed or inhaled. Affects CNS; causes irritation to skin, eyes and respiratory tract. Follow Fire action in case of Fire. Remove to fresh air; If not breathing give artificial respiration; if it is difficult give oxygen. Give large amount of water to drink. Immediately flush with water. Sodium borohydride Highly flammable, toxic, contact with water liberate flammable gases. Toxic in contact with skin and if swallowed, very toxic by inhalation; causes burns and react violently with water. Hexane Flammable liquid; harmful if swallowed or inhaled. Irritating to eyes, nose, throat, skin and CNS; over exposure to the vapor may cause Page 41 of 49 Follow fire action in case of fire. Immediately flush with large amount of water. In case of skin, eyes contact flush with copious amount of water. Follow fire action in case of fire. Follow Fire action in case of Fire. Immediately flush with large amount of water.

XYZ/EHS/OEP/01

Methylation

Formic acid

headache, drowsiness. Corrosive and irritating to the eyes, skin, all living tissue and respiratory tract.

Immediately flush with large amount of water.

Formaldehyde

Poison, danger; suspect cancer hazard; may cause cancer; vapor harmful if inhaled or absorbed through skin. Causes irritation to skin, eyes, and respiratory tract; Strong sensitizer, causes blindness if swallowed; flammable liquid and vapor.

Follow Fire action in case of Fire. Remove to fresh air; If not breathing give artificial respiration; if it is difficult give oxygen. Give large amount of water to drink. Immediately flush with water.

IPA. HCl

Flammable liquid; harmful if swallowed or inhaled. Irritating to eyes, nose, throat, skin and CNS; over exposure to the vapor may cause headache, drowsiness.

Follow fire action in case of fire. Immediately flush with large amount of water.

3. Product Name Sr. no 1 Type of Reaction Cyanation Critical raw material 2,3-Dichloro benzoyl chloride Cuprous cyanide Poison; Danger; may be fatal if swallowed, Possible Hazards Corrosive Action In case of contact wash off immediately with water. A cyanide antidot kit should be available in

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inhaled or absorbed through skin. Contact with acid liberates poisonous gas; causes severe eye irritation and possible burn. Affect blood, cardiovascular system, CNS and thyroid. Acetonitrile Keep away from heat and swallowed, inhaled or absorbed through skin; causes burns to any area of contact. Toluene Keep away from heat and swallowed, inhaled or absorbed through skin; causes burns to any area of contact. Hexane Flammable liquid; harmful if swallowed or inhaled. Irritating to eyes, nose, throat, skin and CNS; over exposure to the vapor may cause 2 Condensation and cyclisation Sulfuric acid headache, drowsiness. Vapor may cause pulm irritation and eye irritation; severe chem. burn to eyes and skin 4. Product Name Sr. Type of Reaction Critical raw Possible Hazards

any cyanide work area. In case of cyanide poisoning start first air treatment and flush skin with plenty of water.

Follow Fire action in Immediately flush with large amount of water.

ignition source; harmful if case of Fire.

Follow Fire action in Immediately flush with large amount of water.

ignition source; harmful if case of Fire.

Follow fire action in case of fire. Immediately flush with large amount of water.

Remove to fresh air, Resuscitate if not breathing; flush with plenty of water.

Action

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no 1

Dehydroiodination

material Iodine

Vapor severely irritate and can burn mucous membrane and respiratory tract; excess tears, tightness in chest, headache; inflammation of the nasal mucous, bronchitis, rapid heart beat, diarrhea and wt. loss.

Follow Fire action in case of Fire. Remove to fresh air; If not breathing give artificial respiration; if it is difficult give oxygen. Give large amount of water to drink. Immediately flush with water. Iodine stains can be removed by immediate washing skin by 5% sodium thiosulphate solution.

Pyridine

Irritation of eyes, skin, respiratory tract, chest pain, difficulty in breathing, CNS effects like headache, dizziness, nausea and vomiting, redness or burns of eyes/skin lever or kidney damage.

Inhalation remove to fresh air, Resuscitate if not breathing; flush with plenty of water.

Methanol

Flammable liquid, causes severe eye irritation, may cause blindness if swallowed; may cause skin irritation, CNS depression, and liver, kidney damage.

Follow fire action in case of fire. Immediately flush with large amount of water to any area of contact. Remove to fresh air. If not breathing give artificial respiration; if it is difficult give oxygen. Do not induce

HCl

Poison; danger; corrosive liquid and mist cause severe burns to all body tissue; may be fatal if swallowed or inhaled. Inhalation may cause

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lung damage. Extreme heat of vomiting. Give large contact with metal can release flammable hydrogen gas. amount of water to drink. In case of contact, immediately flush with plenty of water. Follow fire action in case of fire. Sulfuric acid Vapor may cause pulm irritation and eye irritation; severe chem. burn to eyes and skin. Sodium thiosulphate Sodium hydroxide Hesperidin Inhalation, irritation to mucous membrane, mild irritation of eyes and skin. May causes burn to the eyes, skin, respiratory and gastrointestinal tract. May cause skin and eye irritation; may cause respiratory and digestive tract irritation. 5. Product Name Sr. Type of no 1 Reaction Condensation Critical raw material Methanol Possible Hazards Flammable liquid, causes severe eye irritation, may cause blindness if swallowed; may cause skin irritation, CNS depression, and liver, kidney damage. Dimethyl Formamide Poison; danger, combustible; may be fatal if swallowed; inhaled or absorbed through skin. Keep away from heat, sparks and Inhalation remove to fresh air, Resuscitate if not breathing; flush with plenty of water. Action Follow fire action in case of fire. Immediately flush with large amount of water to any area of contact. Immediately flush with large amount of water Immediately flush with large amount of water. Remove to fresh air, Resuscitate if not breathing; flush with plenty of water. Flush with plenty of water.

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flame. Irritation of breathing vapors. Acetic acid Strongly corrosive and causes serious burns. Lachrymator; may cause irritation to eyes, skin and respiratory tract. Immediately flush with plenty of water. Remove from exposure and move to fresh air. If breathing is difficult, give oxygen. Hydrochloric acid Poison; danger; corrosive liquid and mist cause severe burns to all body tissue; may be fatal if swallowed or inhaled. Inhalation heat of contact with metal can release flammable hydrogen gas. Remove to fresh air. If not breathing give artificial respiration; if it is difficult give vomiting. Give large amount of water to drink. In case of contact, immediately flush with plenty of water. Follow fire action in case of fire. Keep away from heat and Toluene ignition source; harmful if swallowed, inhaled or absorbed through skin; causes burns to any area of contact. May cause eye, skin, digestive Chloromethyl aniline tract irritation, liver and kidney damage Immediately flush with plenty of water. Remove from exposure and move to fresh air. If breathing is difficult, give oxygen. Follow Fire action in case of Fire. Immediately flush with large amount of water.

may cause lung damage. Extreme oxygen. Do not induce

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ANNEXURE L
EMERGENCY ORGANIZATION CHART

Site controller

Incident Controller

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Fire fighting Squad

First aid Squad

P & .A. Dept

Engineering Security Dept.

EHS Manager

Shift In charge

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