RISK ASSESMENT & DISASTER MANAGEMENT PMANAGEMENT PLAN...

RISK ASSESMENT & DISASTER RISK ASSESMENT & DISASTER RISK ASSESMENT & DISASTER RISK ASSESMENT & DISASTER

MANAGEMENT PMANAGEMENT PMANAGEMENT PMANAGEMENT PLANLANLANLAN

FORFORFORFOR

PRPRPRPRODUCTION ENHANCEMENT OF ODUCTION ENHANCEMENT OF ODUCTION ENHANCEMENT OF ODUCTION ENHANCEMENT OF

SYNTHETIC DRUGS API (656 TPA TO 1268 SYNTHETIC DRUGS API (656 TPA TO 1268 SYNTHETIC DRUGS API (656 TPA TO 1268 SYNTHETIC DRUGS API (656 TPA TO 1268

TPA AND R & D PRODUCTS (5TPA)TPA AND R & D PRODUCTS (5TPA)TPA AND R & D PRODUCTS (5TPA)TPA AND R & D PRODUCTS (5TPA)

AtAtAtAt

Plot No. 89A/B, 90, 91, F10 & 80, Plot No. 89A/B, 90, 91, F10 & 80, Plot No. 89A/B, 90, 91, F10 & 80, Plot No. 89A/B, 90, 91, F10 & 80,

Pologround Industrial Estate,Pologround Industrial Estate,Pologround Industrial Estate,Pologround Industrial Estate,

Tehsil &Tehsil &Tehsil &Tehsil & District: District: District: District: IndoreIndoreIndoreIndore ((((Madhya PradeshMadhya PradeshMadhya PradeshMadhya Pradesh).).).).

OfOfOfOf

M/s. M/s. M/s. M/s. IPCA IPCA IPCA IPCA LaboratoriesLaboratoriesLaboratoriesLaboratories Ltd.Ltd.Ltd.Ltd.

LIST OF CONTENTS

S. No. PARTCULARS PAGE NO.

1.0 INTRODUCTION 1 1.1 RISK ASSESSMENT 1

1.1.1 THE PURPOSE OF A RISK ASSESSMENT STUDY 1 1.2 RISK ASSESSMENT IN CHEMICAL INDUSTRY 1

1.2.1 ACTIVITIES REQUIRED 2 1.2.2 FLOW CHART OF RISK ASSESSMENT 2

1.2.2.1 PHILOSOPHY 3 1.2.3 METHODOLOGY 3

1.2.3.1 SAFETY ORGANIZATION SETUP 4

1.2.4 DETAILS OF STORAGE OF HAZARDOUS MATERIALS AND CONTROL

MEASURES 4

1.2.5 HAZARDOUS PROPERTIES OF THE CHEMICALS, COMPATIBILITIES AND

SPECIAL HAZARD 9

1.2.6 EMERGENCY PLAN 14 1.2.6.1 BRIEF 14 1.2.6.2 OBJECTIVES 14 1.2.6.3 DEGREE OF EMERGENCY 15 1.2.6.4 ESSENTIAL ELEMENTS OF THE EMERGENCY PREPAREDNESS PLAN 15 1.2.6.5 EMERGENCY PLAN COVERS 15 1.2.6.6 TYPES OF SITE EMERGENCY PLAN 16

1.2.6.6.1 ON SITE EMERGENCY 16 1.2.6.6.2 OFF-SITE EMERGENCY PLANNING 18

1.2.6.7 FACILITIES / SYSTEM FOR PROCESS SAFETY, TRANSPORTATION, FIRE

FIGHTING SYSTEM AND EMERGENCY CAPABILITIES TO BE ADOPTED 18

1.2.6.7.1 PROCESS SAFETY 19

1.2.6.7.2 DETAILS OF INSTRUMENT CONTROL PANEL 20

1.2.6.7.3 SOLVENT RECOVERY 21

1.2.6.7.4 FACILITIES FOR DRUM STORAGE AREA 21

1.2.6.8 FACILITIES OF SAFE TRANSPORTATION OF HAZARDOUS SUBSTANCES 22

1.2.6.9 FACILITIES AT UNDERGROUND STORAGE TANK FARM 22

1.2.6.10 FACILITIES AT ACID STORAGE TANK AREA 23

1.2.6.11 PIPELINES 23

1.2.6.12 EMERGENCY SHUTDOWN 24

1.2.6.13 EMERGENCY CONTROL CENTRE 24

1.2.6.14 EMERGENCY FIRST AID CENTER 25

1.2.6.15 FIRE FIGHTING FACILITY 26

1.2.6.16 MOCK DRILL FOR EMERGENCY 28

1.2.6.17 CRITERIA FOR PROCLAIMING MAJOR EMERGENCY 29

1.2.6.18 OTHER CAUSES OF EMERGENCY SITUATION 30

1.2.7 EHS MANAGEMENT AT IPCA LABORATORIES, INDORE 30

1.2.7.1 DUTIES OF KEY PERSONNEL’S 32

1.2.7.1.1 EMERGENCY OPERATIONS TEAM 32

1.2.7.1.2 EMERGENCY TASK FORCE 32

1.2.7.1.3 PLANT PROTECTION TEAM 33

LIST OF CONTENTS

1.2.7.1.4 THE MAIN SITE CONTROLLER 33

1.2.7.1.5 EMERGENCY CONTROL CONTROLLER 34

1.2.7.1.6 PLANT SUPERVISOR 34

1.2.7.1.7 REPAIR TEAM (ENGINEERING DEPARTMENT) 35

1.2.7.1.8 MEDICAL TEAM 36

1.2.7.1.9 PERSONNEL DEPARTMENT 36

1.2.7.1.10 ENVIRONMENT DEPARTMENT 36

1.2.7.1.11 SECURITY DEPARTMENT 37

1.2.7.1.12 FIRE FIGHTING SQUAD 37

1.2.7.1.13 FIRST-AID SQUAD 37

1.2.7.1.14 GENERAL MASS 38

1.2.7.1.15 TELEPHONE OPERATOR 38

1.2.8 PREVENTIVE MEASURES 38

1.2.8.1 SAFETY ARRANGEMENT IN USE OF HAZARDOUS CHEMICALS 38

1.2.8.2 SAFETY MEASURES TO PREVENT FIRE 41

1.2.8.3 SAFETY ARRANGEMENT & REMEDIAL MEASURES FOR SAFE

OPERATION 43

1.2.8.4 PERSONAL PROTECTIVE EQUIPMENTS (PPES) 45

1.2.8.5 SELF CONTAINED BREATHING APPARATUS 45

1.2.8.6 ASSEMBLY POINTS 45

1.2.9 EMERGENCY MEASURES 45

1.2.9.1 ACTIONS TO BE TAKEN IN CASE OF SUDDEN STOPPAGE OF WORK 46

1.2.9.2 ACTION TO BE TAKEN IN CASE OF FIRE 46

1.2.9.3 ACTION TO BE TAKEN IN CASE OF ELECTRIC SHOCK 48

1.2.9.4 ACTION TO BE TAKEN IN CASE OF CHEMICAL/STEAM BURN OR

CONTACT 49

1.2.9.5 ACTION TO BE TAKEN IN CASE OF INHALATION OF CHEMICAL VAPORS 49

1.2.9.6 ACTION TO BE TAKEN IN CASE OF EYE INJURY BY DUST PARTICLES 49

1.2.9.7 ACTION TO BE TAKEN IN CASE OF BLEEDING 49

1.2.9.8 ACTION TO BE TAKEN IN CASE OF GAS/VAPOR LEAKAGE 49

1.2.9.9 ACTION TO BE TAKEN IN CASE OF FLAMMABLE SOLVENT VAPOR

LEAKAGE/SPILLAGE 50

1.2.9.10 ACTION TO BE TAKEN IN CASE OF AMMONIA LEAKAGE 51

1.2.9.11 ACTION TO BE TAKEN IN CASE OF LEAKAGE / RUPTURE OF

HYDROCHLORIC ACID / SULPHURIC ACID/CAUSTIC LYE/L.D.O TANK 51

1.2.9.12 ACTION TO BE TAKEN IN CASE OF LEAKAGE FO/HSD TANKS 52

1.2.9.13 ACTION TO BE TAKEN IN CASE OF PHOSPHORUS OXY-CHLORIDE

SPILLAGE/LEAKAGE 53

1.2.9.14 ACTION TO BE TAKEN IN CASE OF HAZARDOUS WASTE

LEAKAGE/SPILLAGE 53

1.2.9.15 ACTION TO BE TAKEN IN CASE OF RELEASE & SPILLAGE OF

TOXIC/FLAMMABLE SUBS 54

1.2.9.16 ACTION TO BE TAKEN IN CASE OF FOOD POISONING 54

1.2.9.17 SAFETY MEASURES TO BE TAKEN IN CASE OF STRUCTURE COLLAPSE 54

1.2.9.18 SAFETY MEASURES TO BE TAKEN IN CASE OF ANY FLOOD, HEAVY

RAINS AND STORM 55

1.2.9.19 ACTION TO BE TAKEN DURING EARTHQUAKE 55

LIST OF CONTENTS

1.2.9.20 ACTIONS TO BE TAKEN IN CASE OF TERRORIST ATTACK. 56

1.2.9.21 ACTIONS TO BE TAKEN ON RECEIVING BOMB THREAT 56

1.2.9.22 SAFETY MEASURES TO BE TAKEN DURING STRIKES 57

1.2.9.23 ACTION TO BE TAKEN DURING HEAVY WIND & CYCLONE 57

1.2.9.24 DUTIES OF OUTSIDE AGENCIES/SERVICES 58

1.2.10 PERSONAL HYGIENE 58

1.2.11 PHARMACOVIGILANCE 58

Production Enhancement of Synthetic Drug API (656 TPA to 1268 TPA) and R & D Products (5 TPA) At Plot No.

89A/B, 90, 91, F10 & 80, Pologround Industrial Estate, Tehsil and District Indore, Madhya Pradesh

Risk Assessment & Disaster Management Plan

M/s. Ipca Laboratories Ltd. Page 1

RISK ASSESSMENT & DISASTER MANAGEMENT PLAN

1.0 INTRODUCTION

Risk is the potential that a chosen action or activity will lead to a loss (an

undesirable outcome). Potential losses themselves may also be called "risks". The

risks associated with the chemical industry are commensurate with their rapid

growth and development. Risks is majorly caused by uncertainty in project failures

(at any phase in design, development, production, or sustainment life-cycles),

accidents, natural causes and disasters as well as deliberate attack or events of

uncertain or unpredictable root-cause.

The various chemical disasters that have taken place world - wide both in developed

and developing countries stand a proof to the consequences. The disasters in

chemical industries are generally due to fire, explosion and toxic release.

1.1 RISK ASSESSMENT

It is the identification, assessment, and prioritization of risks followed by

coordinated and economical application of resources to minimize, monitor, and

control the probability and/or impact of unfortunate events or to maximize the

realization of opportunities.

1.1.1 THE PURPOSE OF A RISK ASSESSMENT STUDY

The main objective of the risk assessment study is to propose a comprehensive but

simple approach to carry out risk analysis and conducting feasibility studies for

industries and planning & management of industrial prototype hazard analysis in

Indian context.

Risk analysis & risk assessment should provide detail on Quantitative Risk

Assessment (QRA) techniques used world over to determine risk posed to people

who work inside or live near hazardous facilities, and to aid in preparing effective

emergency response plans by delineating a Disaster management Plan (DMP) to

handle onsite & offsite emergencies.

1.2 RISK ASSESSMENT IN CHEMICAL INDUSTRY

The risks associated with the chemical industry are commensurate with their rapid

growth and development. Apart from their utility, chemicals have their own

inherent properties and hazards like they can be flammable, explosive, toxic or

corrosive etc. The whole lifecycle of a chemical should be considered when assessing





its dangers and benefits. The chemical industries have potential to cause disasters

whose consequences are not only limited to the workers and management, but also

to the society and environment at large. The various chemical disasters that have

taken place world - wide both in developed and developing countries stand a proof

to the consequences. The disasters in chemical industries are generally due to fire,

explosion and toxic release.

1.2.1 ACTIVITIES REQUIRED

Activities requiring assessment of risk due to occurrence of most probable instances

of hazard and accident are both onsite and off-site.

On site

� Emission/spillage etc. from storage & handling

� Exposure to fugitive dust, noise, and other emissions

� Housekeeping practices requiring contact with solid and liquid wastes

Off-site

� Exposure to pollutants released from on site/ storage/related activities

� Contamination due to accidental releases or normal release in combination

with natural hazard

� Deposition of toxic pollutants in vegetation / other sinks and possible sudden

releases due to accidental occurrences

1.2.2 FLOW CHART OF RISK ASSESSMENT

� There are 4 Major tread which will be acquire for the risk management i.e.

Assess Risk, Plan Polices & controls, Implement safeguards, monitor & evaluate

the risk.

1. Ensure that potential safety problems are properly understood.

2. Check whether existing control measures (including emergency plans) are

adequate.

3. Determine what is necessary to reduce risks to a reasonable level

4. Priorities unacceptable risks identified by the assessment and determine

further action

Some of the important points considered to avoid/reduce any kind of hazard in the

industry are:

� Design and Pre-modification review: Proper layout like location of plant in

upwind side of tank farm , fire station away from process area, process area far

from public road and right material selection can reduce severe damages to

the work and outside environment





� Chemical Risk Assessment: Compatibility, storage, fire protection, toxicity,

hazard index rating, fire and explosion hazards

� Process Safety Management: HAZOP, FTA, F&E Index calculation, reliability

assessment of process equipment, incorporating safety trips and interlocks,

scrubbing system, etc. before effecting major process changes, proper

Management of Change procedure (MoC), etc.

� Electrical Safety:Hazardous area classification , protection against static

electricity , proper maintenance of specialized equipment like switchgears,

MCC Rooms

� Safety Audits: Periodical assessment of safety procedures and practices,

performance of safety systems and gadgets along with follow up measures.

� Emergency Planning: Comprehensive risk analysis indicating the impact of

consequences and specific written down and practiced emergency procedures

along with suitable facilities.

� Training: Safety induction and periodical refresher training for the regular

employees and contract workmen shall be carried out.

1.2.2.1 PHILOSOPHY

This report is limited to the following:

� Identification of major risk areas.

� Hazard identification/Identification of failure cases

� Consequential analysis of probable risks / failure cases

• Evaluation of heat radiation & pressure wave profiles for identified

failure cases.

• Risk assessment on the basic of the above evaluation & risk acceptability

• Minimum preventive & protective measures to be taken to minimize

risks to maximum possible extent.

� Giving pointers for effective disaster management

� Suggesting other measures to further lower the probability of risk

1.2.3 METHODOLOGY

The procedure used for carrying out the Quantitative Risk Assessment Study is

outlined below:

Identify Credible Loss Scenarios for the facility under the study by discussion with

IPCA Laboratories Ltd. Simulate loss Scenarios to determine the vulnerable zones for

toxic dispersion, pool fire, Tank on fire (Thermal Radiation ), Flash fire, Explosion





overpressure (Vapor cloud Explosion, Ball fire using software packages HAMSGAP.

Suggest mitigating measures to reduce the damage, considering all aspects of the

facilities. The flowchart of the methodology for the present study is shown in

following page.

Risk assessment study methodology flowchart

Fig 6.2.4 Risk Assessment Study Methodology Chart

Start

Facility, process and meteorological data collection

Listing out of hazardous operations & storage details

Identification of failure scenarios & quantification of

probable hazards associated with them

Defining of parameters for each of chemicals & each of hazards

Defining release type (continuous or instantaneous) & determine

release rates

Simulation of selected cases for consequence modeling

Preparation of summary of consequence results

Evaluation of potential risk to the surrounding population

Discussion & recommendation of mitigate / remedial

measures

End





1.2.3.1 SAFETY ORGANIZATION SETUP

FIG 6.2.4.1 SAFETY ORGANIZATION SETUP

1.2.4 DETAILS OF STORAGE OF HAZARDOUS MATERIALS AND CONTROL MEASURES

TABLE 6.2.5 (A)

HAZARDOUS CHEMICALS AND STORAGE

S. No NAME OF CHEMICAL

MAXIMUM INVENTORY OF HAZARDOUS SUBSTANCES

HAZARD

CATEGORY

MAX.

STORAGE

CAPACITY.

R/N/R/E MODE OF

STORAGE

1. Liquid Ammonia C,T 16T NR Tank

2. Acetone F 6T NR MS Drum/ Tank

3. Caustic flacks C 18T NR Ploy bags

4. Caustic lye C 20T NR Tank

5. Denatured sprit F,T 21T NR Tank

6. Diethyamine F 10T NR MS Drum

7. Dimethyl sulphate F,T - NR MS Drum

8. Hydrochloric acid C,T 37T NR Tank

9. Isopropyl alcohol F 16T NR Tank

10. Meta Chloro aniline T 35T NR Tank

11. Paraformaldehyde T 5T NR Ploy Bags

V.P.

Operations

Manager EHS

EHS Officer

Fire Supervisor-1

Fireman-4& safety Supervisor-I

S.r.G.M

(Corporate EHS)

OHC Full time Doctor and Male

Nurse Ward Boy





12. Phosphorous

Oxychloride

C,T,W 22T NR Carboy’s

13. Sulphuric acid C,T 30T NR Tank

14. Toluene F,T 25T NR U.G. Tank

15. Methanol F 25T NR U.G. Tank

• F = FIRE

• T = TOXIC

• C = CORROSIVE

• E = EXPLOSIVE

• R = REACTIVE

Table 6.2.5 (B)

Hazardous Chemicals & Control Measures to Prevent Accidents

S. No. NAME OF

HAZARDOUS

SUBSTANCE

OPERATING

PRESSURE

AND TEMP.

Risk S/P Existing Safe Guard Emergency

Control

Measure

1. Liquid

Ammonia ATP

Ambient

Human

Fatality • Provision of dyke wall

for spill containment

• Provision of eye wash

cum emergency shower

• Provision of respiratory

& non-respiratory type

PPE’s

• Facility of water curtain

is also available

Fire

Hydrant

System/S

CBA set

OHC with

Doctor/A

mbulance

/rescue

team

2. Acetone ATP

Ambient

Property

Damage/

Human

Fatality

• Provision of covered

shad





PPE’s

• Provision of earthing

with metal rod is

available for dispensing

of materials

Fire

Hydrant

System/SC

BA set OHC

with

Doctor/Am

bulance/res

cue team

3. Caustic flakes ATP

Ambient

Human

Fatality • Provision of eye wash




PPE’s

Fire

Hydrant

System/SC

BA set OHC

with

Doctor/Am

bulance/res

cue team





4. Caustic lye ATP,

Ambient

Human





PPE’s

• Provision of dyke wall


Fire

Hydrant

System/SC

BA set OHC

with

Doctor/Am

bulance/res

cue team

5. Denatured

sprit ATP,

Ambient

Property

Damage/

Human

Fatality





PPE’s




bonding on joint, flame

arrester on vent pipe

Fire

Hydrant

System/SC

BA set OHC

with

Doctor/Am

bulance/res

cue team

6. Diethyamine ATP,

Ambient

Property

Damage/

Human

Fatality

• Provision of covered

shad





PPE’s


with metal rod is


of materials

Fire

Hydrant

System/SC

BA set OHC

with

Doctor/Am

bulance/res

cue team

7. Dimethyl

sulphate ATP,

Ambient

Human

Fatality Fire

Hydrant

System/SC

BA set OHC

with

Doctor/Am

bulance/res

cue team

8. Hydrochloric

acid ATP,

Ambient

Contact

May

causes

eyes, skin

burn.

Irritation

to nose &

lungs





PPE’s



Fire

Hydrant

System/SC

BA set OHC

with

Doctor/Am

bulance/res

cue team

9. Isopropyl

alcohol ATP,

Ambient

Property

Damage/

Human

Fatality




Fire

Hydrant

System/SC

BA set OHC






PPE’s




with metal rod is


of materials

with

Doctor/Am

bulance/res

cue team

10. Meta Chloro

aniline ATP,

Ambient

Human





PPE’s



Fire

Hydrant

System/SC

BA set OHC

with

Doctor/Am

bulance/res

cue team

11. Paraformalde

hyde ATP,

Ambient

Irritation

to eyes • Provision of hand

gloves, goggles & dust

mask

Fire

Hydrant

System/SC

BA set OHC

with

Doctor/Am

bulance/res

cue team

12. Phosphorous

Oxychloride ATP,

Ambient

Human





PPE’s

• Provision of cool dry &

covered shad with

impervious floor

• Neutralization purpose

soda ash & dry sand

available

Fire

Hydrant

System/SC

BA set OHC

with

Doctor/Am

bulance/res

cue team

13. Sulphuric acid ATP,

Ambient

Human





PPE’s



Fire

Hydrant

System/SC

BA set OHC

with

Doctor/Am

bulance/res

cue team

14. Toluene ATP,

Ambient

High

concentra

tion

causes

irritation

of eyes,





PPE’s


Fire

Hydrant

System/SC

BA set OHC

with

Doctor/Am





headache,

fatigue,

drowsines

s, chance

of fire



with metal rod is


of materials

bulance/res

cue team

15. Methanol ATP

Ambient

High

concentra

tion

causes

irritation

of eyes,

headaches

, fatigue,

drowsines

s, chance

of fire





PPE’s




with metal rod is


of materials

Fire

Hydrant

System/S

CBA set

OHC with

Doctor/A

mbulance

/rescue

team

1.2.5 HAZARDOUS PROPERTIES OF THE CHEMICALS, COMPATIBILITIES AND

SPECIAL HAZARD

� F = FIRE

� T = TOXIC

� C = CORROSIVE

� STEL = SHORT TERM EXPOSURE LIMIT

� BP = BOILING POINT

� LEL = LOWER EXPLOSIVE LIMIT

� PPM = PARTS PER MILLION

� UEL = UPPER EXPLOSIVE LIMIT

� SP.GR = SPECIFIC GRAVITY

� VD = VAPOR DENSITY

� ER = EVAPORATION RATE

� H = HEALTH HAZARD CLASS

� F = FIRE HAZARD CLASS

� R = REACTIVE HAZARD

� BR = BURNING RATE

� TLV = THRESHOLD LIMIT VALUE

� NFPA =NATIONAL FIRE PROTECTION ASSOCIATION-usa

� N.A = NOT AVAILABLE

� N.L =NOT LISTED

Production enhancement of Synthetic Drug API (656 TPA to 1268 TPA) and R & D Products (5 TPA)

at Plot No. 89A/B, 90, 91, F10 & 80, Pologround Industrial Estate, Tehsil and District Indore, Madhya Pradesh

EIA/EMP Report


Table: 6.2.6

Hazardous Properties of the chemicals, compatibilities and special hazard

Name

of Chemi

cal

Haz

ard Flas

h Poi

nt 0c

Bp0

c LEL

% UEL

% Sp.

gr.

20 0c

VD Solubilit

y With

Water at

20 0c

NFPA

h f r Hazardous

Combustion

product

TLV/T

WA

PPM

IDLH

PPM Lc50 Carcino-

genic Characteri

stic

Metha

nol CAS#

67-56-

F/T 10 54 5.4 44 0.7

92 1.1 Soluble 1 3 0 Irritating

Vapor 200 6000

LEL 6400

0

ppm

for 4H

rat

No

Toluen

CAS #

108-

88-3

F 4.0 111 1.1 7.1 0.8

7 3.2 Insoluble 2 3 0 Irritating

Vapor generated

50 2000 400

ppmF

or24

Hr

Rat

No

Diethyl

amine CAS # 109-

89-7

T/F 18.0 55.5 1.8 10.1 0.7

1 2.5 Soluble 3 3 0 Carbon and

nitrogen

oxides

25 2000 4000

ppm

4

hour(

s) for

rat

Yes

Caustic

Lye CAS

#1310

73-2

C/T NF 145 NA NA 2.1

3 Soluble 3 0 1 Heat 2

mg/m

3 (1.22p

pm)

10

mg/m

3.

2300

mg/m

3/2H

for

rats

No

Dimet C/T 83.3 188 3.6 23.3 1.3 4.3 Partially 4 2 0 Carbon and 0.1 7 8.6 Yes



EIA/EMP Report


hyl

sulpha

CAS # 77–

78–1

/F 3 5 Soluble sulfur oxides ppm

for

rats

Sulfuri

c Acid CAS #

7664-

93-9

C NA 340 -- -- 1.8

4 -- Water

Reactive 3 0 2 Non

combustible 1

mg/m3 15

mg/m3

510 mg/m

3

for2H

Rat

No

Hydro

chloric

acid

C/T NA 100 NA NA 1.0

1 0.6

2 Soluble 3 0 0 NA 7.5

mg/m3 50 3124

ppm

for

rats

Not for

humans

Meta

Chloro

aniline CAS#

108-

42-9

C 123 232 NA NA 1.2

16 4.4

1 Insoluble

(<1

mg/mL at

64° F)

2 0 0 Highly toxic

gases Not

establi

shed

550

mg/m

3/4H

for

mous

e

No

Aceton

CAS#

67-64-

1 99

F -20 56 2.15 13.0 0.7

91 2.0

0 Soluble 1 3 0 Irritating

Vapor 750 2500

0 LEL - No

Isopro F 18.5 82.3 2.3 12.7 0.7 2.1 Miscible 1 3 0 Acid smoke 400 2000 - No



EIA/EMP Report


pyl

alcohol CAS #

67-63-

85 & fumes

LEL

Phosp

horus

oxychl

oride CAS

1002

87-3

C NF 107.

2 NA NA 1.6

75 5.3 Reacts

exotherm

ically

4 0 2 Hydrochlori

c and

phosphoric

gases,

poisonous

gases

including

phosphorus

oxides &

chlorides

0.1 - 32

ppm/

4H for

rat

No

Ammo

nia

liquor. CAS

#1336

21-6

Toxi

c -- 36 16 25 0.9 1.2 Miscible 3 1 0 Not

combustible 25 300 2000

ppm/

4-hr

No

Denatu

red

Spirit CAS #

64-17-

F 55 78.3 3.3 19 0.7

90 1.6 Soluble 0 3 0 CO & CO2 1000

pppm 3300

ppm 2000

0 ppm

for 10H

rat

No



EIA/EMP Report


Caustic

Flakes CAS #

1310-

73-2

C NA 1390 NA NA 2.1

3 >1.

0 Soluble

exotherm

ically (111

g/100 g

of water)

3 0 1 No 2 mg /

m3 250

mg/m

3

160

mg /l

24h

(static

) for

fish

(Cara

ssiusa

uratu

s)

Yes



EIA/EMP Report


1.2.6 EMERGENCY PLAN

1.2.6.1 BRIEF

An emergency which may cause serious injuries, loss of life, extensive damage to

property or environment or serious disruption inside the plant, or the events that are

commonly having serious implications like major fire hazards, causing serious burns to

personnel resulting in collapse or structures or release or toxic substances in the

environment.

The emergency plan, in brief, involves noticing an emergency by an

employee/supervisor summoning of declarer of Emergency by shift production

executive, declaring of emergency with or without shutting the plant by sounding the

coded siren, controlling of emergency, performing rescue, leakage control and repair

functions by respective teams till the Works Incident Controller reaches to site. Work

Incident Controller (Department Head) will inform Works Main Controller and Internal

Message Relay Person (Manager- HR) about site emergency and making available all the

resources for the safety and security of the people inside the plant. Manager- HR will

keep liaison with outside agency, Government Authorities and Media. Works Main

Controller will give approval of sounding of all clear signals after having complete

control over emergency to indicate that everything is normal again.

1.2.6.2 OBJECTIVES

The main objectives of the site Emergency Plain is Effective mobilization of resources in

order.

� To save lives

� To rescue injury

� To minimize injury

� To identify the dead

� To contain the incident and to minimize the extent of the damage to the

resources and the business.

� To inform relatives of casualties.

� To secure the safe rehabilitation of affected area

� To provide reliable information to Government Officials and Police.

� To preserver relevant records, equipments and samples which may be

needed as evidence for subsequent investigation.



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1.2.6.3 DEGREE OF EMERGENCY

Disaster can be classified in 3 types depending on its effects:

� LOW - can cause injury, illness and equipment damage but not very serious and

quickly manageable.

� MID - Critical situation, can cause serious injuries to personnel, serious illness

property and equipment damage.

� HIGH - Catastrophic situation, major danger, can cause death, major widespread

illness, injuries, loss of major property and equipments. Immediately uncontrollable.

The above contingencies will be declared by the chief coordinator. The following will

be the mode of action during different degrees of disaster.

� HIGH EMERGENCY- Catastrophic condition. All employees to be evacuated. Local

administration to be properly informed and interacted.

� MID EMERGENCY- All project activities to be stopped. All employees to be in safe

place. To be ready for High disaster situation. Inform local administration.

� LOW EMERGENCY- Activities in the affected area stopped. To be ready for MID

disaster condition.

1.2.6.4 ESSENTIAL ELEMENTS OF THE EMERGENCY PREPAREDNESS PLAN

The important elements to be considered in plan are

� Emergency organization

� Emergency Facilities.

� Roles and Responsibilities of Key Personnel and Essential Employee.

� Communications during Emergency

� Emergency Shutdown of Plant & Control of situation.

� Rescue Transport & Rehabilitation.

� Developing Important Information.

1.2.6.5 EMERGENCY PLAN COVERS

� Identification and assessment of hazards and risks.

� Identification and equipping Emergency Control Centre.

� Identifying Assembly, Rescue points, Medical Facilities.

� Effective communication of the nature of emergency to authorities within the

organization.

� Safeguard people in and outside the works.

� Maintenance of orderly public relation. Provide information to media & government

agencies.

� Identify causalities notify their relatives and render necessary help to them.



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� Termination of Emergency.

� Rehabilitate area affected

� Appraisal of Local Hospitals/Nursing Homes/Doctors on specific emergency

treatment required for persons affected

� Preserve record/ equipment for subsequent enquiry.

� Formulation of plan and of emergency sources.

� Training, Rehearsal & Evaluation.

� Action on Site.

1.2.6.6 TYPES OF SITE EMERGENCY PLAN

1.2.6.6.1 ON SITE EMERGENCY

The onsite emergency / Disaster control plan out lays the detailed sequence of steps to

be followed by plant personnel in case such an eventuality occurs in chemical. It details

out of the management system that would work at the time and defines the location,

responsibilities and step by step studies of Emergency Officers. It also forms the basis of

Mock-Drills to be carried out at least once a quarter to prepare and improve upon the

state of preparedness to tackle any emergency as well as update the onsite Emergency

Plan as when necessary.

A. The Onsite Emergency Plan is divided in 3 Parts:

o Pre Emergency Activities

o Activities During Emergency

o Post Emergency Activities

i.) During Normal Time

� To keep the required emergency equipment in stock at right places and ensure the

working condition.

� To keep the concerned personnel fully trained in the use of emergency equipment.

� To give immediate warning tooth surrounding localities in case of an emergency

situation arising.

� To mobilize transport and medical treatment of the injured.

� To get help from the local community and government officials to supplement

manpower and resources.



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� To provide information to media & Government agencies, Preserving records,

evidence of situation for subsequent emergency etc.

ii.) During An Emergency

� To increase thinking accuracy and to reduce thinking time.

� To localize the emergency and if possible eliminates it.

� To minimize the effects of accident on people and property.

� To take correct remedial measures in the quickest time possible to contain the

incident and control it with minimum damage.

� To prevent spreading of the damage in the other sections.

� To mobilize the internal resources and utilize them in the most effective way

� To arrange rescue and treatment of causalities.

iii.) The overall objectives of the plan are:

� To localize the emergency and if possible eliminate it

� To minimize effects of the accident on people and property

B. Scope of On-Site Emergency Plan

The obligation of an occupier of hazardous chemicals to prepare an on – site emergency

plan is stipulated in Rule 13 of the Manufacture & following Acts:

� Section 41B (4) of the Factories Act, 1948 (as amended)

� MSIHC Rules, 2000.

Also states that every occupier is to draw up an on-site emergency plan with detailed

disaster control measures.

It is therefore necessary to develop an on-site disaster management plan through a

systematic study of the hazard possibilities.



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On Site Emergency Plan Coordination and Action Plan Flow Chart

1.2.6.6.2 OFF-SITE EMERGENCY PLANNING

The off-site emergency plan is an integral part of any hazard control system. It should be

based on those accidents identified by the works management, which could affect

people and the environment outside the works. Thus, the off-site plan follows logically

from the analysis that took place to provide the basis for the on-site plan and the two

plans should therefore complement each other. The key feature of a good off-site

emergency plan is flexibility in its application to emergencies other than those

specifically included in the formation of the plan. The roles of the various parties that

may be involved in the implementation of an off-site plan are described below. The

responsibility for the off-site plan will be likely to rest with the local authority as there

is no locality and factory in the vicinity of the plant at present.

1.2.6.7 FACILITIES / SYSTEM FOR PROCESS SAFETY, TRANSPORTATION, FIRE FIGHTING

SYSTEM AND EMERGENCY CAPABILITIES TO BE ADOPTED

Following facilities and system will be installed

Site In charge – Detect the Emergency, Inform Department Head

– Sounding Alarm & Act for controlling emergency

Department In charge – Work Incident Controller

Top Management Works Main

(Declare Emergency) Controller Manager (HR) Internal

Message Relay Person

Outside Agencies & Govt. Authority

Medical aid Team Emergency arrangement of Transport



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1.2.6.7.1 PROCESS SAFETY

Industry has selected a Forward feed four effect system to suit the requirement. The

Feed from the feed balance tank shall be pumped to a series of the shell & tube type heat

exchangers using the vapors of each effect as a heating media.

Pre-heated feed from feed pre-heaters is feed to Forced circulation calendria and then

passed through the next Forced circulation evapoartor. The Vapors from the preceding

effects are used as a heating medium on the shell side of next calendria. The part of the

solution is recycled back to the same effect to maintain the flow characteristics.

Sufficient areas have been provided on each effect to ensure effective heat transfer.

Vapor liquid separators mounted at the Top part of Forced circulation calendria, with

tangential entry are provided to ensure the efficient separation of liquid and vapors.

These shall be of adequate capacity with sight glass/light glass and manholes.

For circulation specially designed highly efficient Axial Flow pump has been provided.

Product is extracted by means of a product pump.

An efficient thermo compressor designed by M/s. Croll Reynolds Inc. USA is mounted on

the vapors separator 1 which compresses the vapors from the same effect and discharge

to shell side of calendria – 1 as heating media. The dry saturated steam at 8 kgs/cm2 (g)

is used as motive.

Vacuum Pump designed by M/s. Croll Reynolds Inc., USA connected to a barometric

condenser to maintain the desired vacuum pump. All Safety measures will be adopted

from the design stage. Static earthing provision will be made at design stage to all

solvent handling equipments, reactors, vessels & powder handling equipments. Further

all the vessels will be examined periodically by a recognized competent person under

the Factory Rules.

All the vessels and equipments will be well earthed appropriately and well protected

against Static Electricity. Also for draining in drums proper earthing facilities will be

provided. All solvents and flammable material storage tanks will be away from the

process plant and required quantity of material will be charge in reactor by pump.

Jumpers will be provided on all solvent handling pipeline flanges. Caution note, safety

posters, stickers, periodic training &Updation in safety and emergency preparedness

plan will be displayed and conducted. Flame proof light fittings will be installed in the



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plant. All the Plant Personnel will be provided with Personal Protection Equipments to

protect against any adverse health effect during operations, leakage, spillages or splash.

PPE like Helmets, Safety Shoes, Safety Glasses, and Acid-Alkali Proof Gloves etc. will be

provided to the employees. All employees will be given and updated in Safety aspects

through periodic training in safety. Material Safety Data Sheets of Raw Materials &

Products will be readily available.

Interconnecting Piping with all valves and fittings for feed, product, condensate shall be

provided within the battery limits. An Instrument control panel is provided as per

details.

1.2.6.7.2 DETAILS OF INSTRUMENT CONTROL PANEL

An Instrument Control Panel manufactured from MS CRCA Sheet duly powder coated

and supported on legs is provided for operation of the plant.

A screen printed mimic diagram indicating process flow is displayed with illuminated

lights showing various electrical motor in operation. Control panel is pre-wired

complete with necessary electrical relays, fuses, push buttons, indicating lamps,

contactors, etc.

a. Level indicator and controller for vapor liquid separators complete with level

sensor, electro-pneumatic control valve, actuator, positioned and I/P converter.

b. Temperature indicator (Digital type) for all vapor separators

c. Level indicator for feed tank, balancing tank and High/low level alarm, pump

operation should be hooked up with level switches.

d. Absolute pressure indicators for vapor separator

e. Pressure gauges for incoming steam line and cooling water line.

f. Diaphragm type pressure gauges on each recirculation pumps

g. Pressure control loop to control the steam pressure in first effect calandria shell

complete with pressure transmitter, I/P converter, control valve etc (Interlocking

with Feed tank level switch).

h. Steam Flow meter with totalizer

i. Flow indicator and totalizer for feed

j. MCC Panel for all the drives with required spare feeders

k. PLC based control panel, which will have starter & safety for all motors, indicators,

alarm, etc. for automatic operation of the plant.

l. Level Transmitter along with Control Valve – 4 nos.



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1.2.6.7.3 SOLVENT RECOVERY

1. Reactor is provided with primary and secondary condensers.

2. They are connected with necessary cooling arrangement like Brine, Chilling, Cooling

water etc.

3. Frequent descaling of condensers is done to avoid the scaling of condensers.

4. For effective recovery efficient condensers has been installed after ensuring

required HTA.

5. Steam pressure to Re-boiler is controlled to avoid excess vapour generation.

6. Jacketed receiver with chiller brine or chilled water is provided to collect the

distilled solvent.

7. Insulation of Chilled Water Condensers and Jackets of receivers.

8. Increase of Cooling / Chilling Water Line size and ensuring adequate pressure.

9. Solvent storage tanks have been provided with suitable breather valves.

10. Mechanical seal pump are used for handling of solvent.

1.2.6.7.4 FACILITIES FOR DRUM STORAGE AREA

� Only general shift material is being handled.

� FLP type light fittings will be provided.

� Proper ventilation will be provided in godown.

� Proper label and identification board /stickers will be provided in the storage

area.

� Drum pallets will be provided.

� Drum handling trolley / stackers will be used for drum handling.

� Separate dispensing room with local exhaust and static earthing provision will be

made.

� Materials will be stored as Compatibility and separate area for flammable,

corrosive and toxic chemical drums in store.

� Smoking and other spark, flame generating item will be banned from the Gate.



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1.2.6.8 FACILITIES OF SAFE TRANSPORTATION OF HAZARDOUS SUBSTANCES

1. Class A petroleum products will be received through road tanker and stored in

underground storage tank as per petroleum rules.

2. Road tanker unloading procedure will be in place and will be implemented for safe

unloading of road tanker.

3. Static earthing provision will be made for tanker unloading.

4. Earthed Flexible Steel hose will be used for solvent unloading from the road

tanker.

5. Fixed pipelines with pumps will be provided for solvent transfer up to Day

tanks/reactors.

6. Double mechanical seal type pumps will be installed.

7. NRV provision will be made on all pump discharge line.

8. Some chemicals will be received at plant in drums by road truck and stored in a

separate drum store

9. Transport Emergency planning and training to driver and cleaner will be

provided.

10. TREM card will be provided to transporter.

11. On way emergency telephone number list will be provided to transporter.

1.2.6.9 FACILITIES AT UNDERGROUND STORAGE TANK FARM

1. Class A petroleum products will be received through road tanker and stored in

underground storage tank as per petroleum rules.

2. Tank farm will be constructed as per explosive department requirement and

separation distance will be maintained.

3. Static earthing provision will be made for road tanker as well as storage tank.

4. Flame arrestor with breather valve will be provided on vent line.

5. Road tanker unloading procedure will be prepared and implemented.

6. Fire load calculation will be done and as per fire load Hydrant System will be

provided as per NFPA std. and Fire extinguishers will be provided as per fire load

calculation.

7. Spark arrestor will be provided to all vehicles in side premises.

8. Flame proof type equipment s and lighting will be provided.

9. Lightening arrestor will be provided on the top of chimney.



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10. Trained and experience operator will be employed for tank farm area.

11. NFPA label (hazard identification) capacity and content will be displayed on

storage tank.

12. Solvents will be transferred by pump only in plant area and day tank will be

provided. Overflow line will be return to the storage tank or Pump On-Off switch

will be provided near day tank in plant.

13. Jumpers will be provided on solvent handling pipe line flanges.

14. Flexible SS hose will be used for road tanker unloading purpose and other temp

connection.

1.2.6.10 FACILITIES AT ACID STORAGE TANK AREA

� Storage tank will be stored away from the process plant.

� Tanker unloading procedure will be prepared and implemented.

� Caution note and emergency handling procedure will be displayed at unloading

area and trained all operators.

� NFPA label will be provided.

� Required PPEs like full body protection PVC apron, Hand gloves, gumboot,

� Respiratory mask etc. will be provided to operator.

� Neutralizing agent will be kept ready for tackle any emergency spillage.

� Safety shower, eye wash with quenching unit will be provided in acid storage area.

� Material will be handled in close condition in pipe line.

� Dyke wall will be provided to all storage tanks, collection pit with valve provision.

� Double drain valve will provided.

� Level gauge will be provided on all storage tanks.

� Safety permit for loading unloading of hazardous material will be prepared and

implemented.

� TREM CARD will be provided to all transporters and will be trained for

transportation emergency of Hazardous chemicals.

� Fire hydrant system with jockey pump as per TAC norms will be installed.

1.2.6.11 PIPELINES

The various pipelines to transfer i.e. charging, draining etc. in the plant will be

periodically inspected for Support, Vibration, Corrosion conditions, Painting, and Color

Code. Pipelines and Flexible pipeline (SS 316/MS) are appropriately earthed to avoid



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accumulation of Static Electricity. Periodic Checkups of the pipelines will be conducted

to curb any chances of mishap due to leakages. Preventive Maintenance Schedules will

be in practice.

1.2.6.12 EMERGENCY SHUTDOWN

Sudden stoppage of work or failure in energy distribution system due to a serious

breakdown would causes severe potential risks to the plant as well as surroundings,

therefore has to be dealt with a high degree of technical competency by the plant

personnel. The actual would depend on the real cause of the stoppage and the state of

interrupted operations.

Process shutdown may only be under taken as per the specific route and stage of

reaction mixture and parameters expressly ordered by Plant In- charge of production.

In case the course of the reaction deviate from normal, process stoppage has to be

undertaken and under such a situations safety takes absolutely priority over yield and

output.

A few guidelines are furnished below to give desired direction to the actions which

would have to be taken:-

1. All the charging valves into the equipment must be checked to ensure that they

are closed.

2. All the valves on heating side must be checked to ensure that they are closed.

3. As far as possible utility services to be made available to bring interrupted

operation within safe and stable stages.

1.2.6.13 EMERGENCY CONTROL CENTRE

� Telephone operator at ground floor of administration building intercom no. 111

� Security room near Main Gate or Administration Building

� This is the place from where the operation to handle the emergency is directed

and coordinated. It will be attended by the works main controller, key personnel,

the senior officer of the fire and police service etc.

� The emergency control centre is equipped with the following:

� Adequate number of P & T phones

� STD facilities & E-mail



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� EPBX system which will enable immediate contact to any location inside the

factory.

� The drawing and plan of factory illustrate:

� Area where there as large inventories of hazardous material e.g. tanks &

drums storage, compressed gas cylinder are stored etc.

� Location of safety equipment storage

� Fire water system & alternative source of water

� Factory entrance & road system

� Assembly points, casualty treatment system.

� Additional drawings and plans of the factory to illustrate during the emergency:

� Development of emergency vehicles and personnel

� Area where particular problem may arise

� Areas evacuated

� Note pads, pans, pencils etc.

� Nominal roll or employees

1.2.6.14 EMERGENCY FIRST AID CENTER

� First aid centre near main gate, houses on “Doctor available in general shift.

Otherwise also trained ambulance driver are available in each shift.”

� Besides 15 nos. of First Aid Stewards trained by St. John Ambulance of India are

working in the factory. First aiders (6-7) are available in each shift.

� All likely useful medicines along with oxygen cylinder are stretures are available

here.

� The record for the blood group of individual employee is also available in the First

Aid Centre. In emergency, if blood is required, the same list can be referred.

� The factory has also arrangement with ESI,Arpan&Sasi nursing home/hospital for

getting consulting services for employees and in case of an emergency injured can

be directly admitted here.

First Aid Medical Facilities

The company has provided “First –AID” boxes at security office. Following are the

contents of First aid.

1. Tincture iodine.



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2. Eye wash solution.

3. Burnol

4. Soframycin (ointment)

5. Sterilized cotton wool.

6. Band-aid.

7. Antiseptic Solution (Dettol)

8. Bandage.

9. Paracetamol tablets.

10. Iodex

11. Pair of scissor.

12. List of Antodotes

1.2.6.15 FIRE FIGHTING FACILITY

A. Source of Fire

i. Electrical Sub Station/ MCC.

ii. Methanol, HSD and other solvents.

B. Line of Action:-

i) Any person who notices, any sign of fire or accident shall immediately attract

the nearby employees by shouting and seek help from them. Push the Manual

call Point. Try to extinguish/ control the fire by using appliances available near

the site. Do not be panicky.

ii) Duties of Official:- The officials receiving the warning shall forthwith inform on

following

a. Fire fighting station

b. Security main gate

c. Plants Manager

d. Unit Head of Plant

After giving information reach the spot, remove Men & Machinery and take steps to

tackle the fire in accordance with the fire fighting instructions. Inform Hospital to get

Ambulance if required.

Fire Protection Systems



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These systems are proposed to protect the plant by means of different fire protection

facilities and consist of

� Hydrant system for exterior as well as internal protection of various

buildings/areas of the plant.

� Portable extinguishers and hand appliances for extinguishing small fires in

different areas of the plant.

� Water cum foam monitor to be provided in bulk fuel storage area.

� Fire water pumps.

Motor driven pumps each of sufficient capacity and head are proposed for the hydrant

systems which are capable to extinguish Fire or cooling purpose.

Hydrant System

Adequate number of fire hydrants and monitors are provided at various locations in and

around the buildings and other plant areas. The hydrants will be provided on a network

of hydrant mains drawing water from the hydrant pump, which starts automatically due

to drop of pressure in the event of operating the hydrant valves. It is proposed to go for

TAC approved hydrant system for foolproof safety and benefit from fire policy premium.

Hydrant Pump Details

S. No Pump Driven By H.P RPM Head Capacity

1 Main Diesel Oil 92 1800 70M 121 KL/hr

2 Main Electricity 75 2955 70 M 121 Kl/hr

3 Jockey Electricity 10 2880 70 M 10.8 KL/hr

Tank Capacity

S. No. Tank Capacity

1 Fuel 200 l

2 Water 1,35,000 l

3 Priming 1,00 l

Hydrant System

S. No. Hydrant System Nos. (Approx.)

1 Single Hydrant 23



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2 Foam Monitor 02

3 Water Monitor 01

4 Fire Hose Box 23

5 Fire Hoses 46

Fire Extinguishers and Others

S. No. Others Nos.

1 Fire Extinguishers (Foam/DCP & CO2) 116

2 ABC Type Fire Extinguishers 05

3 Eye Wash safety shower 20

Emergency Escapes

The objective of the emergency escape is to escape from the hazardous locations, to the

nearest assembly point or the other safe zone, for rescue and evacuation.

Wind Sock

Wind socks for knowing wind direction indication would be provided at a suitable

location to visible from many locations. It is proposed to install windsocks at plant and

Administration Building so as to be visible from different locations in the plant.

1.2.6.16 MOCK DRILL FOR EMERGENCY

Mock drills are organized to train workers to act in any emergency situation. These

guide workers to behave and react to the emergency situation. This can prevent loss of

life of workers. Below is the procedure and plan of action of organizing Mock Drills.

� Manager (Safety) fixes-up the date and area of Mock Drill in consultation with Sr.

GM. (Safety) and Head of Works on the day of the Mock Drill. The time of drill may

or may not be fixed before hand in order to check the emergency preparedness of

the plant personnel during surprise Mock Drill.

� The Mock Drill for chemical leakage and fire is carried out at least quarterly as per

the Onsite Emergency / Disaster Control plan.

� Manager (Safety) observes the activities at the site of Mock Accident and note

down the violations occurring during the exercise.

� Manager (Safety) / Safety Coordinator will be stationed at ECC. He observes the

activities at ECC and notes down the overall reaction of plant personnel as well as



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the deviations / violations occurring during the exercise.

� Manager (Safety) prepares Mock Drill report as per Format stating the sequence of

events with timings, the deviations /violations, the reasons, necessary actions for

compliance with /improvement upon the Plan, Process Heads responsible for

necessary action & target dates.

� Manager (Safety) circulates the Mock Drill Report copy to Head of Works & all

Process Heads responsible for Mock Drill Plan compliance within two working

days.

� Manager (Safety) monitors and presents the status of improvement actions, based

on last Mock Drill, in the next statutory safety committee meeting. The actions to

be taken further are recorded in statutory safety committee MOM.

� Onsite Emergency Plan is updated, if necessary, based on the findings of Mock

Drill. Updating of On-site Emergency Plan is authorized by CEO with adequate

justifications.

� After updating, all the employees, especially the key persons as per On-site

Emergency Plan, are informed and/or trained suitably, if required, before the next

Mock Drill.

1.2.6.17 CRITERIA FOR PROCLAIMING MAJOR EMERGENCY

A major emergency situation can occur in the event of:

a) Fire:

Fire can take place inside the plant/ various departments / Stores/ Paints,

solvents and Oil Storage yards offices and other areas inside the site.

Areas Vulnerable to fire Hazard:

� Solvent Drum Storage room

� Acid Storage Tank

� Production Area, Quality Control

� Boiler House/incinerator

� Furnance Oil & High Speed Diesel Storage Tank

� Packing Material Stores/Raw material store



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� L.P.G. Block at canteen.

� Scrap Yard

b) Explosion:

Explosion followed by fire or fire followed by explosion. These could take place

inside the plant/ Storage yards & Stores.

c) Release of Toxic/ corrosive Gas or Bulk spillage of Chemicals:

The released of toxic/corrosive gas/ chemicals can create a major emergency

situation in view of the quantities stored, the procedure outlined to handle the

emergency situation is to be followed with respect to:

� Evacuation and assembly of personnel to a safe place.

� Taking appropriate steps for bringing the situation under control.

Areas Vulnerable to Release of Toxic/ corrosive Gas or Bulk spillage of

Chemicals:

� Acid/Alkali/Fuel Storage tanks

� Organic solvents & its vapor in the entire production buildings

d) Food Poisoning Contamination of Water

� Drinking water points in the Plant.

Areas Vulnerable to Food Poisoning/Contamination of Water

� Canteen

� Drinking Water Points in plant

1.2.6.18 OTHER CAUSES OF EMERGENCY SITUATION

� Structure collapse

� Floods

� Earthquake

� Bomb Threat

� Food poisoning

1.2.7 EHS MANAGEMENT AT IPCA LABORATORIES, INDORE

� An environmental, Occupational Health and Safety Management System cell exists

which monitors the legal compliance and the environmental parameters in the plant

premises.



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� There is a well equipped occupational health center with round the clock trained

first aider. There is an ambulance available with oxygen facility.

� The effluent from various plants is analyzed for the constituents. At ETP, the

effluents are treated and part of the treated water is recycled to the plant for plant

utility. Rest of the treated water is used for horticulture activities. There is no

discharge of the treated water to outside the factory premises.

� The gaseous emissions from the plant are scrubbed using water or caustic as a

scrubbing media and it is some of the resultant dilute acid effluent is sent back to

the plant. Balance is treated at the effluent treatment plant, where it is converted

into useful product & recycled back to the plant.

� The Periodic checks and prevents the unsafe practice and condition in the plant

areas through daily, weekly, monthly & Quarterly audit of the plant. It ensures the

procurement of appropriate quality of PPEs and its use. It identifies the EHS related

training needs and provides safety training to all employees and contract labor.

� It conducts investigation of accidents, Near Miss & Non-Conformance and suggests

corrective and preventive measures.

� There are Three Tier EHS committees to discuss and resolve safety & environment

related problems / issues.

� There is Area EHS Committees practically covering all plant areas / activities.

� There is Statutory EHS committee to review & monitor legal compliances

� There is Apex EHS Committee to review the Safety Performance of all committees as

well as overall safety performance of plant.

� Mock drills are organized once a quarter to check the preparedness, based on On-

site Emergency Plan.

� At the time of joining every factory based regular employee is required to undergo

compulsory safety training and has to clear the safety examination. Refresher Safety

training is organized at regular basis. In addition to this need based training are also

organized.

� IPCA Laboratories also organizes EHS Promotional activities on the eve of National

Safety Day, Fire safety day & World Environment day etc. IPCA Laboratories is



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committed for a cleaner, greener & safe environment and continual improvements

are carried out in various areas towards safety, health & environmental protection.

1.2.7.1 DUTIES OF KEY PERSONNEL’S

Once the alarm is raised, the work emergency procedure will be activated. As part of

them nominated key personnel will have specified responsibilities. They should appoint

their deputies to act in their deputies to act in their absence or incapacity. The scope of

individual responsibilities is specified on following pages:

1.2.7.1.1 EMERGENCY OPERATIONS TEAM

In an unlikely event of occurrence of an emergency, the shift in charge will inform the

situation to the Site Incident Controller who in turn will inform to Site Main Controller.

The Site Main Controller will take complete control of the plant and coordinate for

handling the emergency. He will direct the activities with various teams as specified

below:

� Emergency Task Force

� Plant Protection Team

� Medical Team

� Security Team

� Man Power Accounting team & search team

� Repair Team

� Community Development Team

1.2.7.1.2 EMERGENCY TASK FORCE

� This team will directly fight the emergency under the leadership of the Site

Incident Controller as per the instruction given by the Site Main Controller.

� On hearing the emergency the Site Incident Controller will establish

communications with the Site Main Controller and start handling the Emergency

directly. This group leader is the Site Incident Controller is the Shift-In charge of

the Incident plant/ section.

� The Emergency Task Force consists of the shift In Charge, Safety Personnel/Fire

Men, Operators, Electrical and Mechanical Technicians of the affected section.



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1.2.7.1.3 PLANT PROTECTION TEAM

This team will ensure the safety of the remaining part of the plant. They will take

instructions from the Site Main Controller as to whether a plant shut down is to be taken

and implemented the decision of the Site Main Controller. If required, they will request

for additional man-power from assembly point.

This team consists of the Shift-In-Charge and Operators of the remaining plant areas.

1.2.7.1.4 THE MAIN SITE CONTROLLER

� General Manager assigned as a Site Main Controller during emergency.

� If he is not available DGM-HR & Admin will act as a Site Main Controller.

� During night shift “Night Shift Manager” will act as SMC

� On receipt of the emergency call, he will coordinate with SIC and assess the

situation

Responsibilities

� Declare On Site Emergency if required (Through Blowing emergency Siren)

� Coordinate and arrange Emergency Task Force for speedy control of the incident

� Guide Emergency Tash Force about the actions to be taken

� Advice other departments for their action such as safe shut down of the plant,

man-power arrangements etc.

� If required call in key personnel and outside and outside services like:

� Fire Brigade

� Doctor

� Ambulance

� Water tankers

� Police etc.

� Establish communication and liaison with agencies like News, TV, Radio and

Government authorities etc.

� Guide & Control the traffic movements in the works

� Ensure that the casualities are attended to.



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� Ensure that the relatives of casualities are informed

� Inform to Occupier about the emergency and action taken to overcome it.

� Declaring “All Clear Signal” after emergency over by blowing continuous siren

� Control the clean up and re-habilitation of affected areas after the emergency

� Arrange the personnel to be relieved in time and ensure that they are provided

with food and drink.

1.2.7.1.5 EMERGENCY CONTROL CONTROLLER

Responsibilities

� Head – EHS

� If he is not available, Shift In Charge- Security will act as an Emergency Control

Coordinator

� Proceed to the scene of incident

� Liase with outside agencies like fire brigade, ambulance etc.

� Liase with the Site Main Controller, Site Incident Controller, Security officer and

Emergency Control Room in fire fighting operations, evacuation procedure and

cordoning off the areas and other measures depending upon the situations

� Inform Site Main Controller regarding progress of the situation and give technical

guidance from safety point of view as may be warranted

� Assess the situation and guide Site Incident Controller and others in containing

the situations

� Investigate cause of incident and make a preliminary report with the practical

remedial measures to prevent similar emergencies/incidents

� Initiate a draft of report to be sent to Government Departments

� Liase with Factory Inspector with the permission of Site Main Controller.

1.2.7.1.6 PLANT SUPERVISOR

Plant Supervisor will act as a Site Incident Controller during emergency. In his absence,

Shift In-charge of the affected plant will act as a Site Incident Controller.

Responsibilities:

� On hearing of emergency, he should rush to the incident spot and take charge of



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over all situations

� Assess the size and nature of emergency

� Decide if major emergency existing or is likely to happen

� Inform the Site Main Controller about the gravity of the situation and ask for help

if required

� Advice Site Main Controller to declare On Site Emergency if required

� Direct the emergency task force to carry out all operations in the affected area

with the priority for safety of personnel

� Minimize damage to the plant, property and environment

� Instruct the plant protection team to take shut dowm and arrange for evacuation

of persons from the plant and areas likely to be adversely affected. By the

emergency

� Direct rescue and firefighting operations at site.

� Coordinate with emergency service at site

� Ensure that all key personnel and outside help are called in and reach the spot

� To ensure timely rectification of unsafe conditions which caused the emergency?

� To ensure that the endangered area is isolated by shutting doors and windows if

required

� Search for casualities and arrange proper aid for them

� Evacuate non-essential persons from the incident spot to safe location

� Collect all relevant information. Arrange for photograpg if necessary and submit

the report. Preserve evidence for enquiry.

1.2.7.1.7 REPAIR TEAM (ENGINEERING DEPARTMENT)

Responsibilities:

� Engineering- in Charge & Electrician & Mechanical Technician should report to the

Site Incident Controller for all engineering support.

� If required isolate power supply

� If required arrange for alternative power sources i.e. D.G.

� They will try their level best to ensure that chilled water, brine and pneumatic

supply remain normal in emergency



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� Be nearer to the accident spot to assist Site Incident Controller.

1.2.7.1.8 MEDICAL TEAM

Responsibilities

� Factory Medical Officer and Male Nurses

� Send ambulance to the affected area

� Provide necessary first aid assistance and arrange for providing medical facilities

outside the premises

1.2.7.1.9 PERSONNEL DEPARTMENT

Responsibilities

� DGM-HR & Time Office Representatives

� Report at assembly point and follow the instruction of the Site Main Controller

� To take roll call at assembly points and identify missing personnel

� Inform Site Main Controller and Site Incident Controller of missing

� To ensure those casualties receive adequate attention and are hospitalized. Inform

their relatives

� Initiate action to inform statutory authorities as may be directed by the Site Main

Controller

� Liase with Government Department officials with permission of Site Main

Controller.

1.2.7.1.10 ENVIRONMENT DEPARTMENT

� Proceed to the scene of incident

� Assess the situation and guide Site Incident Controller and others in containing

the situations

� To ensure that emergency is confined in restricted zone

� Liase with the Site Main Controller, Site Incident Controller, Security officer and

Emergency Control Centre in firefighting operation, evacuation procedure and

cordoning off the area, and other measures depending upon situation.

� Inform Site Main Controller regarding progress of the situation and give technical

guidance from Environmental Department point of view as may be warranted.



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� Initiate a draft of report to be sent to Pollution Control Board

� Liase with Pollution Control Board Authorities with the permission of Site Main

Controller.

1.2.7.1.11 SECURITY DEPARTMENT

� Once hearing an emergency call, he should immediately rush to the respective

gates.

� Control entry traffic and attend the calls

� Only company officials to be allowed in. No visitors except fire brigade, doctor,

police and other government officials to be allowed inside

� Cordoning off the accident site

� Help in shifting of injured to the hospital by arranging the transport

� Search the areas of causalities

� Post a guard at accident Site in order to prohibit unauthorized entry and see that

area in undisturbed till the investigation is over

� Liase with police authorities with the permission of Site Main Controller

� Keep main gate and approach road clear so that if outside emergency vehicles are

needed, the road will not be blocked.

1.2.7.1.12 FIRE FIGHTING SQUAD

� Personnel trained in firefighting operations should reach the accident spot

immediately and report to Site Incident Controller at the site

� Determine the cause of fire and accordingly use suitable sire extinguisher to

extinguish the fire

� Do not allow others to come near fire

� Adopt laid down procedure for firefighting and evacuation purpose

1.2.7.1.13 FIRST-AID SQUAD

� Personnel trained in first-aid procedure should reach the accident spot

immediately and report to the Site Incident Controller at the site

� Identify injured and help in evacuation operation

� Assess the cause and nature of injury



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� Give first aid & CPR accordingly

� Id condition is serious accompany them t hospital as may be directed by Site

Incident Controller.

Contractor

� If accident is within your area of work, stop all work and report to the assembly

points in the queue

� Take a roll call of your workers and inform Head count team immediately if any

person is missing

1.2.7.1.14 GENERAL MASS

� If the danger is not in your area/building & you are not trained either in first aid

or fire fighting keep doing your own job (overcrowding my endangered area)

� If danger exists in some corner of your building & you are not trained either in fire

fighting or first-aid, stop/close reactor or equipment as per SOP & follow the

instruction of supervisor. Assemble at specified safe zone. Stay there till the clear

siren is given

1.2.7.1.15 TELEPHONE OPERATOR

� On hearing emergency siren the Telephone operator will not leave the EPBX room

and will inform the Key Personnel about emergency and coordinate with Site Main

Controller

1.2.8 PREVENTIVE MEASURES

1.2.8.1 SAFETY ARRANGEMENT IN USE OF HAZARDOUS CHEMICALS

Number of hazardous /dangerous chemicals is used in the plant. Handling & Storage of

these chemicals are given in the plant. Handling and Storage of these chemicals are

given special care in view of the inherent hazards associated with them. All such

materials are handled according to laid down safety procedure to avoid accidents and

minimize health hazards.

Following types of safety arrangements are made in the plant:

(1) For Flammable Chemicals: These include gases and solvents.

A. PRECAUTIONS

� Flammable materials are stored in places which are cool enough to prevent



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accidental ignition of the vapor mix with the air.

� The storage area situated away from any source of heat or fire hazard.

� Chmeical stored as per chemical in compatibility

� When highly volatile & flammable liquids are stored, any electrical light fiting or

apparatus are of certified flame proof construction

� No open lights or flames (Smoking, welding & cutting etc.) are permitted in or near

the storage space.

� The storage room, tank, installations are electrically grounded and periodically

inspected.

� Firefighting equipments are readily available near storage area.

B. HANDLING

The risk of any physical injuries of material damage of both often occur during handling

the chemical due to carelessness, adopting usage work methods and practices,

ignorance of the properties of the chemicals. This is minimized by observing following

guidelines

C. GUIDELINES

� The containers or dangerous substances are used on first come first out basis

� Dangerous substances are checked for the compliance of labeling procedure

� Special care is taken to prevent breakage to containers of dangerous substances

� Empty containers of dangerous substances are discarded only after ther are

thoroughly decontaminated

� Incompatible chemicals are stored separately

� Wherever necessary workers engaged in loading, unloading operations they are

given necessary personal protective equipments

� As far as possible these substances are kept in their original containers

� Unauthorized entry at loading & storage area is made strictly prohibited

� Materials received in drums, boxes, carboys etc. are transported on pallets using

hand trolleys, forklift trunks etc,

� Gangways of 1 m wide be provided between the stacks/row of containers.



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(2) Toxic Chemicals: It includes ammonia, toluene etc.

Precautions

� Storage areas are well ventilated

� If the substances stored are likely to decompose due to contact with heat, moisture,

acid etc. they are stored in cool, well-ventilated place out of direct sunrays, water,

heat& ignition source.

� They are not stored along with food stuffs & other edible substances

� Persons are not allowed to work alone in a storage are containing highly toxic

substances

(3) Corrosive chemicals: These includes strong acids, alkalis etc.

Precautions

� Such materials may cause damage to their containers & leak into atmosphere of the

storage area resulting into corrosion to metal structures. Hence sound container,

made of proper material are used for storage purposes

� The container are checked frequently for any leakage/damage any leaked/damaged

containers are immediately replaced

� Such material storage area are properly isolated from the rest plant

� Storage area are made of impervious wall and floor with provision of safe disposal

of spillage

� Storage area are well ventilated

� All metallic structures & parts are painted with anticorrosive paint.

(4) Water Reactive Chemicals: This includes phosphorus oxy chloride, sulphuric

acid etc.

Precautions

� Storage area is well ventilated cool and dry

� No water hydrant, hydrant sprinkler water or foam type fire extinguishers, water

type area places/used in the area

� Building is water proof, located on high ground & separated from other storage



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(5) Oxidizing Chemicals: The chemical which acts as source of oxygen & can supply

oxygen to a reaction even in absence of air

Precaution

� Such chemicals are stored in a cool and well ventilated area

� Away from the liquids of low flash point

� The storage area is of the fire proof construction

Labeling

All above mentioned chemicals either they are solids. Liquid or gas comes in the

container various shapes, size & MOC. They are properly labeled so that person can

understand the nature and hazard associated with substances in the container/package

1.2.8.2 SAFETY MEASURES TO PREVENT FIRE

� To prevent Fire, the entire factory premises have been declared as "NO SMOKING"

zone.

� No spark-producing job is being allowed inside the plant, Tank Farm area & other

areas without Hot Work Permit.

� Emergency Siren is available to warn about Fire emergency. Sound the Siren as

soon as possible after observing the fire.

� No vehicle is allowed to move in front of Methanol Tank farm area without having

spark arrestor.

� Fire-fighting systems installed in the factory are - Portable Fire Extinguishers, Fire

hydrant system and fixed Foam Flooding System to fight Methanol / HSD fire.

� Entire fire-fighting system (Extinguishers as well as hydrant system) is

inspected/audited in a phased manner once in a 6 week cycle and record is

maintained in 4.4.7_CL-01 (for extinguishers) and 4.4.7_CL-02 (for hydrant

system).

� Once in a 2 months Fire systems Audit is done by External Agency as per 4.4.7_CL-

03 and record is maintained in 4.4.7_F-01.

� The checking of the fixed foam flooding system is done as per 4.4.7_CL-04 under

the supervision of PM MAP (Safety) and PM MWE (Security & Admin.).



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� On the Job drill is done once a week and record maintained.

� The Fire sub-process (Security & Admin.) has been given the operational

responsibility for Foam Flooding system, but process person as well as MAP

(MP&U) can also operate the system.

� Any change in the type and/or location of the Fire extinguisher/ Hydrant /Foam

system will be through MAP (Safety) and the change would be sent to drawing

office through EWR for updation.

� Head of P&A carries out monthly review of the Fire Management.

� Trained Fire fighting Security men are available in each shift.

� Four assembly points are provided where person can be assembled & evacuated if

required.

� Fire escape staircase is provided in all plants.

� Trained First-Aides & mail nurse are available in each shift.

� Fire proximity suit is available and can be used if valve isolation & other jobs are

required in fire vicinity.

� In case of emergency shift In charge / JE are trained & required to evacuate / shut

off the plants in short notice. They have to follow the responsibility of Technical

Coordinator.

� It is in practice to provide earthing before starting loading/ unloading of

flammable chemicals. This is to dissipate static charge.

� Medium velocity water sprinkler system has been provided on Methanol tank.

� After fire fighting operation the water/ foam inside the dyke wall is to be collected

in containers / drum with the help of portable pump & same should be transferred

to ETP.

� Fire hydrant system as per NFPA norms will be installed in the plant. Hydrant

system & sprinkler system will be provided as per requirements.

� It is proposed to have a provision for separate Water storage tank for fire water as

well as process water requirements.

� D.G. Sets will be provided for emergency power.



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� Tele Communication system and mobile phone will be used in case of emergency

situations for communication.

� First Aid Boxes and Occupational health centre will be made at site.

� In case of water comes out of dyke wall or if fire takes place in tanker the water

used for firefighting will go to storm water drain. Storm water drain to be isolated

and all the water used in fire fighting shall be collected and transferred to ETP.

1.2.8.3 SAFETY ARRANGEMENT & REMEDIAL MEASURES FOR SAFE OPERATION

A. SAFE OPERATING PROCEDURE:

� Written safe operating procedure available for all operations

� The written safe operating procedure are displayed or made available and

explained to the workers

� Workers have been informed of the consequences of failure to observe the same

operating procedure

� Contract workers are educated and trained to observe safety at work place

B. Work Permit System

� Necessary type of work permits for carrying out hazardous operation exists in

factory

C. Waste Disposal System

� Identification done for various types of waste available

� Waste is disposed off in environment friendly methods as consented by MPPCB

D. Personal Protective Equipment (PPE)

It has been provided to the employees as per the requirement. Adequate inventory of

both respiratory & non-respiratory PPE’S is maintained. These PPE’S are kept at easily

approachable strategic locations for use in case of any emergency:

� List of required PPEs for each area/operation has been developed and the

required PPEs are made available to the workers.

� Safety Department and the workers are consulted in the selection of PPEs

� Workers have been trained in proper use of PPEs

� Arrangements for the safe custody and storage of PPEs are provided



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� Regular inspections and replacement, if required, of all PPEs is done.

E. Emergency Preparedness

� There is an on-site emergency plan for factory

� Mock Drills are conducted of on-site emergency plan

� Location of emergency control centre, assembly points have been fixed

� Suitable and adequate protective and rescue equipment are made available

� Water hydrant system and fire extinguisher are made available in every work area

� Required numbers of emergency showers are provided

� Arrangements for alternate power source is made

F. Plant Layout and area classification

� Plants buildings and utilities are well segregated and approachable by Pacca Road

� Hazardous zones in the plant for electrical installation have been identified,

accordingly flameproof electrical fittings are provided

� Periodic Inspection of Preventive maintenance of electrical installation is done by

a qualified person and record is maintained

G. Static Electricity

� The process and equipments generate and accumulate static charge have been

identified

� All such equipment are properly bonded and earthed

� Periodic inspection for earthing system is done

H. Pressure Vessel (Fired & Un-fired)

� Safety valve & rupture disk are provided on the pressure vessels/pressure plants

so that pressure will not exceed their maximum working pressure for which it is

designed

� Testing & examination done by competent person

I. Material Handling

� There are adequate storage facilities available

� Areas are clearly defined

� Workers follow safe procedures for storage of materials



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� Contractor workers are trained in safety

1.2.8.4 PERSONAL PROTECTIVE EQUIPMENTS (PPES)

Tabl6 6.2.9.4

List of PPEs Used

S. No. Name of the Item

1 Safety Helmet

2 Safety Goggles

3 Safety Belt

4 Spare Cartridge- Ammonia, Acid, organic and multipurpose

5 Ear Muffs/ Ear Plugs

6 Air supply respirator/hood

7 Hand gloves

8 PVC Apron

9 Safety Shoes

10 Gum Boot Full

11 Cartridge/canister mask

12 Heat Resistant hand Gloves and cut resistant hand gloves

13 Surgical Hand Gloves

14 Fire Fighting Suit (Location)

15 Face Shield

16 SCBA

1.2.8.5 SELF CONTAINED BREATHING APPARATUS

SCBA is present at main gate.

1.2.8.6 ASSEMBLY POINTS

Wherever any emergency is declared, employee are required to assemble at following

locations, as per the decision of the Unit Head / Plant Manager at Time

Office/Personnel dept near main gate No. 1

� Normally the wind direction in this area is either west to east. Hence, this is ideal

location for assembling the masses

� In case, above area is also likely to be affected then employees should assemble

near gate No. 2

1.2.9 EMERGENCY MEASURES- Risk when factory is out of operation & recommended

counter safety measures.



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1.2.9.1 ACTIONS TO BE TAKEN IN CASE OF SUDDEN STOPPAGE OF WORK

Sudden stoppage of work or failure in energies distribution system due to a serious

breakdown would cause severe potential risks to the plant as well as surroundings,

therefore has dealt to high degree of technical competency by the plant personnel. The

actual would depend on the real cause of the stoppage & the state of interrupted

operations. A few guidelines are furnished below to give desired direction to the

actions which would have to be taken.

� Process shut down may only be undertaken as per the specific route & stage of

reaction mixture & parameters expressly ordered by plant in-charge/production

manager

� All the valves on heating side must be checked to ensure that they are closed

� As far as possible utility services to be made available to bring interrupted

operation within safe and stable stages.

1.2.9.2 ACTION TO BE TAKEN IN CASE OF FIRE

All concerned personal should take following steps in case of fire:

� Person who spots fire should not go panicky

� First he should spot exact location of fire and assess the situation, then shout “Fire

Fire” at the top of his voice. Unit head, Head EHS and Security should be informed

on Intercom at once. Below given are personnel to be informed and their intercom

numbers

Emergency No.: 160

Factory Manger: 105

Security: 116/117

Safety Officer: 126

� On hearing the emergency, security shall put the emergency siren. On hearing for

help/alarm all trained person should reach the site of the incident at the earliest.

� Send word to the supervisor & Department head.

� Immediately extinguish fire with the help of fire extinguisher available. Only

trained and experienced



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� Affected person if any should be removed from the place and first aid shall be

given quickly by trained person

� Other person who are not concerned with actual firefighting operation should

evacuate the place

� The area should be condoned off and no unauthorized person should be allowed

to reach near the place of fire

� If necessary, isolate power supply to the affected area

� If necessary, plant may be shut down in safe manner

� The flammable material should be shifted to safer place

� Whenever necessary cool nearby structures/equipments/storage vessel to

reduced effect

� During the firefighting operations position on windward side so that fumes do not

affected you

� If required, use self contained breathing apparatus

� If fire gets uncontrollable help from respective sources like Fire Brigade, etc.

should be called for

� Clear road from traffic obstruction

� Brief the firefighting personnel of the cause of fire and wherever use of water is

considered dangerous

� When the firefighting personnel of the cause of fire and wherever use of water is

considered dangerous

� When fire is extinguished do not leave the place immediately re-check the place

thoroughly

� Used fire extinguisher to be sent for refilling and unused ones should be put back

in its original location’

� Water tanks should be refilled to its capacity

� The affected area should be evacuated and cordoned off immediately

� Check the wind direction and determine if neighboring industries are in danger, if

so inform unit head/safety officer/production manger. If danger is immense



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inform concerned head.

� Inform to security on the intercom Nos. 116/117 & safety officer on 126

� Only trained and experienced personnel approach the area using suitable

protective equipments like SCBA or Airline Masks/Hood

� Ensure that only essential personnel are in the affected areas. Others should

assemble at assembly point. Approach from the window and doors to prevent any

entry of leaked gases

� Source of leakage should be traced out and the system to be isolated from other

equipments

� Leaked gases/chemicals should be trapped in suitable scrubbers

� If required flame proof pedestal fans may be used to bring down the gas

concentration within limit such decision should be taken in consultation with

plant in-charge

� Affected persons should be provided with necessary medical aid

1.2.9.3 ACTION TO BE TAKEN IN CASE OF ELECTRIC SHOCK

� Dissociate the casualty from the electrical contact

� Switch off the main supply.

� Remove the electric wire by help of dry wooden/plastic bar.

� The rescuer should stand on dry wooden plate/ rubber mat etc.

� Immediately inform to Fire & Safety personnel.

� Don’t touch the casualty by bare hands even after the cutting of electric supply.

� To dissipate the static charges from the body of casualty,

� Check breathing rate of the injured person.

� Give him artificial respiration viz:

� Mouth to mouth respiration.

� Pressing of chest 15 times in 7.5 seconds etc.

� Give him any mild hot drinks.

� Refer to hospital



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1.2.9.4 ACTION TO BE TAKEN IN CASE OF CHEMICAL/STEAM BURN OR CONTACT

� Take the affected person away from source.

� Remove contaminated clothing.

� Put affected body part under emergency shower for 10 minutes.

� Shift injured person (s) to First Aid Centre.

� Assess the situation to shift the person to hospital, if needed.

� Refer MSDS (Material Safety Data Sheet) of the concerned chemical.

1.2.9.5 ACTION TO BE TAKEN IN CASE OF INHALATION OF CHEMICAL VAPORS

� Stop the leakage of vapours.

� Shift injured to area having fresh air.

� If breathing is affected, give artificial respiration by resuscitators or mouth to

mouth.

� Shift injured to First Aid centre.

� After revival, shift him to hospital for further check up.

� Refer MSDS (Material Safety Data Sheet) of chemical.

1.2.9.6 ACTION TO BE TAKEN IN CASE OF EYE INJURY BY DUST PARTICLES

� Clean the eye with clean water for 5 minutes. Use eye wash Fountain.

� Cover the affected part & do not rub the eyes.

� Shift injured to First Aid centre

1.2.9.7 ACTION TO BE TAKEN IN CASE OF BLEEDING

� Clean the affected area.

� Stop/minimize bleeding by applying thumb pressure or putting bandage.

� Shift injured to First Aid centre.

1.2.9.8 ACTION TO BE TAKEN IN CASE OF GAS/VAPOR LEAKAGE

� The affected should be evacuated and cordoned off immediately

� Check the wind direction & determine if neighboring farms are in danger. If so,

inform Unit Head/GM/Safety Manager/ Production Manager.



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� If damage is immense inform concerned unit

� Inform on intercom No.

Security: 116/117

Head EHS: 126

� Only trained & experienced personnel approach the area using suitable Personal

Protective Equipment like Self Contained Breathing Apparatus.

� Ensure that only essential personnel are in the affected areas. Others should

assemble at assembly point. Approach from the windward side so that escaping

gas/vapor is carried downwind and you are not exposed to it

� Rescue person trapped/ injured. Ask them to put wet cloth on nose and mouth for

evacuation.

� Person present in other buildings should close their window and doors to prevent

any entry of leaked gases

� Source of leakage should be traced out and the system be isolated from other

equipments if required, pedestal fans may be used to bring down the gas

concentration within permissible limit. Such decision should be taken in

consultation with plant in charge/production manager

� Leaked gases/chemicals should be trapped in suitable scrubbers

� If required Flame proof pedestal fans may be used to bring down the gas

concentration within limit such decision should be taken in consultation with

plant in-charge

� Affected persons should be provided with necessary medical aid.

1.2.9.9 ACTION TO BE TAKEN IN CASE OF FLAMMABLE SOLVENT VAPOR

LEAKAGE/SPILLAGE

� The affected area should be evacuated and cordoned off immediately.

� Heat and ignition source in the vicinity should be removed immediately

� Use appropriate PPE’s while entering in the area.

� Keep CO2 or DCP type fire extinguisher ready.

� Plug the leakage.



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� Transfer the liquid a safe container.

� If there is any doubt, consult MSDS of particular solvent.

� Petrol/diesel engine driven vehicles should not be allowed to enter plant area.

� Ensure that flammable material do not enter storm water drain

� If leakage is inside plant, exhaust fan may be started for early dissipation of vapor.

� Spilled material should be absorbed on dry sand or clay

� Contaminated sand or clay should be incinerated in Incinerator

1.2.9.10 ACTION TO BE TAKEN IN CASE OF AMMONIA LEAKAGE

Besides general measures suggested in general precautions, following actions to be

taken:

� The affected area should be evacuated and cordoned off immediately.

� Only trained & experienced personnel should approach the area using Self

Contained Breathing Apparatus (SCBA) or Supplied Air type Hoods, Body

Protective PVC overall, Hand Gloves Gum Boots. Etc.

� The location of ammonia leak may be determined by moving an open bottle of

dilute hydrochloric acid in the suspected region. A white cloud of ammonium

chloride will form.

� If leakage is form cylinder, emergency safety kit may be used for stoppage of

leakage

� If leakage is from pipeline or equipment, supply from cylinder should be cut off.

� The leaked ammonia may be dissolved in water by application of water spray.

� Creep close to the floor to take advantage of the lower concentration of the gas at

that level as ammonia is lighter than air so it will rise up in the air.

� If necessary, help of Safety Manger and Security should be taken

� A water hose at the point of leakage will be of help in case of ammonia leakage.

� Doors & Windows may be opened and exhaust fans be started to remove the

ammonia vapors.

1.2.9.11 ACTION TO BE TAKEN IN CASE OF LEAKAGE / RUPTURE OF HYDROCHLORIC ACID

/ SULPHURIC ACID/CAUSTIC LYE/L.D.O TANK

� Area should be evacuated immediately and cordoned off.



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� Affected persons should be thoroughly washed using clean water and give

necessary medical aid.

� Personnel entering the area should make use of suitable Personal Protective

Equipment.

� Leaked tank should be depressurized immediately by transferring remaining

quantity into another tank / container.

� Leakage source should be traced out and plugged.

� In case of L.D.O do not bring heat source nearby

� If Possible spilled material should be contained in dyke and transferred into a

container.

� If nor then the same should be observed on sand or earth.

� Sand/earth contaminated with acid/alkali should be first be neutralized then

dumped at safe place.

� Sand/earth contaminated with oil should be burned in incinerator

� Absorbing in saw dust or other combustible material should be avoided.

� If spilled material gets into the trench of electric cables, it should be drained with

natural gradient and washed with large quantity of water continuously de-

energizing the first

� If spilled material gets into the storm water drain, it should be washed with large

quantity of water and collected in Effluent Treatment Plant. The collected liquid

should be either neutralized or oil layer should be removed manually.

1.2.9.12 ACTION TO BE TAKEN IN CASE OF LEAKAGE FO/HSD TANKS



necessary medical aid.

� Personnel entering the area should make use of suitable Personal Protective

Equipment.

� Leaked tank should be depressurized immediately by transferring remaining

quantity into another tank / container.

� Leakage source should be traced out and plugged.

� In case of L.D.O / L.S.H.S do not bring heat source nearby

� If Possible spilled material should be contained in dyke and transferred into a

container.



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1.2.9.13 ACTION TO BE TAKEN IN CASE OF PHOSPHORUS OXY-CHLORIDE

SPILLAGE/LEAKAGE

� The affected area should be evacuated and cordoned off immediately

� Trapped & injured personnel should be removed

� Affected persons should be provided with necessary medical aid

� Cover all spills with sufficient amount of soda ash

� Doors and windows may be opened and exhaust fans be started to remove the

vapors of phosphorus oxy-chloride

� Only trained and experienced personnel should approach the area using SCBA,

body protective PVC suit, hand gloves, gum boots etc.

1.2.9.14 ACTION TO BE TAKEN IN CASE OF HAZARDOUS WASTE LEAKAGE/SPILLAGE

� Personnel entering the area should make use of suitable Personnel Protective

Equipment.


� Only trained an experienced person approach the area with give necessary

medical aid.


necessary treatment. Leaked drum should be immediately transferred into mother

drum / container.

� Or leakage’s point should be traced out and plugged.

� Do not bring heat source nearby.

� If possible spilled material should be contained in dyke and transferred into a

container. (Normally Hazardous Waste drums are kept on impervious flooring

under DYKED area so as to accident leak/spill.)

� If not then the same should be absorbed on sand or earth

� Sand/earth contaminated with hazardous Waste should be first collected in

specified drums then incinerated.

� If spilled material gets into the storm water drain. It should be washed with large

quantity of water and collected in Effluent Treatment Plant. The collected liquid

should be either neutralized or oil layers should be removed manually.



EIA/EMP Report


1.2.9.15 ACTION TO BE TAKEN IN CASE OF RELEASE & SPILLAGE OF TOXIC/FLAMMABLE

SUBS

� All Plants are open and well ventilated.

� Personnel Protective equipment such as SCBA, Safety goggles, Full suit, Gum boot,

gloves are provided & available in each plant/ section.

� Safety Showers and eye wash fountains are provided at strategic locations.

� Four assembly points are provided where person can be assembled & evacuated if

required.

� Red cordoning strips are available for isolating the affected area.

� Remove all non-required persons from the area.

� PA system is available to communicate the emergency.

� Windsocks to assess the air direction have been provided at strategic locations.

� Air monitoring to measure the concentration of toxic chemical.

� MSDS of all chemical available in each Plant/ Deptt.

1.2.9.16 ACTION TO BE TAKEN IN CASE OF FOOD POISONING

In case of suspected food poisoning or contamination of water, following guideline may

be followed:

� Quickly ask the conscious casualty what has happened, remember that he may

lose consciousness at any time.

� Immediately take action to prevent further distribution/use of contaminated

food/water.

� Place the casualty in the recovery position.

� If conscious, give him plenty of fluids to drink.

� Do not induce vomiting.

� If consciousness is lost, follow the standard “Artificial Resuscitation Procedure.”

� If in doubt, arrange removal to hospital.

1.2.9.17 SAFETY MEASURES TO BE TAKEN IN CASE OF STRUCTURE COLLAPSE

� In case section is getting affected by structure collapse, immediately stop all

operations and deploy all available persons in removing the machinery / raw

material / finished goods / packing material.



EIA/EMP Report


� Ascertain that there are no casualties and if there are then arrange to shift the

same to hospital.

� Inform engineering personnel for isolation if required.

� Ensure that the report of the incident is sent in time to the concerned personnel.

1.2.9.18 SAFETY MEASURES TO BE TAKEN IN CASE OF ANY FLOOD, HEAVY RAINS AND

STORM

� In case section is getting affected by flood, immediately stop all operations and

deploy all available persons in removing the machinery / raw material / finished

goods / packing material so that they are not affected by flood.

� Inform engineering personnel for isolation if required.

� Housekeeping department in consultation with HR department to ensure

dewatering. Arrangement of portable dewatering pumping may be done, if

required.

� Store in charge in coordination with the security department to ensure that the

raw materials/ finished goods pallets are fully covered and properly tied with

tarpaulin.

� If required, finished goods and raw material shifting from the area that is flooded

to be carried out under the surveillance of the store in charge.

� All those not concerned, stay inside the strong and safe building till instructed by

the authorized, keep the doors and windows closed.

1.2.9.19 ACTION TO BE TAKEN DURING EARTHQUAKE

Indore falls in a seismic zone with low portability for earthquake, although a crisis

situation arising out of earthquake cannot be ruled out. I t may be noted that the

construction of most of the buildings are now seismic proof, however, following

procedures should be adopted in case of a situation so demands to save life and

property:

� Do not panic and keep calm. Employees to quickly evacuate to the assembly area

near to the gate no. 1(Assembly point no. 1)

� Avoid using lift and staircase only be used for evacuation.

� All movements should be made along the main wall of the structure, if trapped

should remain near the main wall of the structure or the main piller.



EIA/EMP Report


� In case of earthquake, immediately stop all operations, cut off the electrical supply

and evacuate all persons from the block to the assembly point on top priority.

� Security department in consultation with HR Department should do the head

count immediately at the assembly area and the number of trapped inside the

building should be ascertained to effect evacuation after the tremor stabilizes.

� On declaration of emergency, evacuate people to a safe location and arrange to

take head count.

� Shut down the whole plant in case of emergency declaration.

� The gate people will call for additional ambulances from local hospitals if needed.

� On discontinuation of emergency, clearance from plant engineering manager to be

obtained for restarting the section / plant.

� Concerned outside agencies for appropriate aid to be contacted at the earliest.

1.2.9.20 ACTIONS TO BE TAKEN IN CASE OF TERRORIST ATTACK

� The employees should not panic and remain inside the building. Close all windows

and doors.

� Evacuation should never be considered, unless a major fire has erupted and

evacuation is inevitable.

� Effect immediate rescue and treatment. Provide proper communication and

controlled guidance.

1.2.9.21 ACTIONS TO BE TAKEN ON RECEIVING BOMB THREAT

Usually bomb threats come in anonymous telephone calls, although they could be

mailed or hand delivered.

If a bomb threat is received during office hours it should be reported immediately to the

company incident controller, AGM Admin and HR , who in turn should inform the

Managing Director confidentially and immediately.

If a bomb threat is received after office hours, Shift In Charge should immediately

contact the GM – Production and AGM Admin and HR who will take the appropriate

action, including informing the employees.

As soon as it is clear that the caller is making a bomb threat, you should get the full

message precise and also listen for clues as to:

� The caller's sex and approximate age



EIA/EMP Report


� Noticeable condition affecting speech, such as drunkenness, laughter, anger,

excitement, incoherence

� Peculiarities of speech, such as foreign accent, mispronunciation, speech

impediment, tone and pitch of voice

� Background noises audible during the call, such as music, traffic, talking and

machinery

When the caller has given his message, try to keep him in conversation. Ask if you can

repeat the message so that you can be sure of having understood it. The following are

key questions that should be asked, if possible, after the caller has given the message

� Where is the bomb located?

� What time will it explode?

� What does it look like?

� When was it placed?

� Who are you?

� Where are you?

1.2.9.22 SAFETY MEASURES TO BE TAKEN DURING STRIKES

� Close all the gates to restrict the entry of the unauthorized persons.

� Local police to be intimated immediately.

� All employees to keep calm and act as instructed by the authorized.

� Security department should help the local police to control the situation.

� Lodge FIR with the local police station.

1.2.9.23 ACTION TO BE TAKEN DURING HEAVY WIND & CYCLONE

� Keep all the chemicals drums/containers tightly closed

� Keep the doors and windows closed

� Do not come out from the building during the strong wind

� Remove all loose objects and things from the terrace before the heavy wind

� Stop all hot works

� Do not disturb the shift in charges assigned with specific work for handling

emergency, for any personal reason



EIA/EMP Report


1.2.9.24 DUTIES OF OUTSIDE AGENCIES/SERVICES

S. No. Department Service

1. Police Law & Order, Traffic Control, Security

2. Fire Service Fire Fighting, Rescue and Spill Handling

3. Medical First Aid- Hospital Treatment

4. Village & NGO’s Evacuation, Support to Industry, Police & Medical

1.2.10 PERSONAL HYGIENE

Direct contact should be avoided between operators, hands and starting materials,

primary packaging materials @ intermediate or bulk products. This ensures quality of

product and thus the product available is free from any infection or contamination.

Changing rooms are provided with photographs which describes the procedure. A high

level personal hygiene is maintained.

1.2.11 PHARMACOVIGILANCE

IPCA lab commits to ensure safety of drugs beyond mere compliance. Drug safety is

monitored from the discovery of medicine throughout the life of the drug. Drug safety is

an important consideration for all stakeholders involved with drugs (Health care

professionals, Consumers & Pharmaceutical companies). IPCA has initiated

Pharmacovigilance activity to ensure drug safety and defeat even any rare adverse

event which can surface the drug anytime during their lifecycle.

Pharmacovigilance function comprises of the following:

� Detection

� Assessment & evaluation

� Understanding and

� Prevention

IPCA has comprehensive system in place for detecting and rapidly evaluating potential

risk due to adverse report of medicines. IPCA assess the adverse event reports

published in medical journals and scientific literature and received from health care

professionals & consumers from countries, where IPCA's products are marketed. IPCA



EIA/EMP Report


also evaluate safety of their products through clinical trials and post marketing

surveillance studies. Sales representatives are trained both in domestic and

international market on various aspects of Pharmacovigilance and adverse event

reporting. Necessary actions are taken based on the assessment of the adverse event

reports.

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