3.05A - Onsite Emergency Plan - Rev 10 - 2013

ON SITE EMERGENCY PLAN
AND
DISASTER CONTROL MEASURES
AT
MUKAND LIMITED, KALWE
BELAPUR ROAD, DIGHE.
P.O. KALWE, DIST, THANE
PIN 400605
Revision No.
10
Revision date
10th January, 2013
ON SITE EMERGENCY PLAN

INDEX
Sr.
No.
CHAPTER
OBJECTIVE
IDENTITY OF FACTORY
HAZARDOUS SUBSTANCES USED / SITUATION IN THE FACTORY
EMERGENCY CONTROL MEASURES
13
SALIENT DOS & DONTS

FIRST AID FACILITIES (IN HOUSE)
EMERGENCY HANDLING FACILITIES (IN HOUSE)
EMERGENCY ORGANISATION CHART
17
EMERGENCY RESPONSE
18
ALARM SYSTEM
EMERGENCY CONTROL CENTRE
ASSEMBLY POINT
FACILITIES IN EMERGENCY CONTROL CENTRE
EMERGENCY EVACUATION
19
PROCEDURES AND DUTIES

KEY PERSONNEL & ESSENTIAL WORKERS
EMERGENCY HANDLING FACILITIES FOR LPG STATION
26
Disaster Management Plant for LPG leakage / Fire
27
10
Other Emergencies
39
11
EMERGENCY MUTUAL AID

NAME OF COMPANIES, PHONE NUMBERS, MEDICAL AID
ARRANGEMENTS.
12
COMMITMENT OF REHEARSAL & REVISION
13
44
DATE OF MOCK DRILLS

SALIENT OBSERVATIONS MADE DURING THE MOCK
DRILLS.
45
IMPORTANT TELEPHONE NUMBERS
RESCUE AUTHORITIES
POLLUTION CONTROL
POLICE
COLLECTOR
FIRE BRIGADE
DIRECTORATE
CIVIL DEFENCE
RELIEF AND
REHABILITATION
MSEB
ASSOCIATION
AMBULANCES
NURSING HOMES
HOSPITALS
MARG MEMBERS
46
CHAPTER 1
OBJECTIVE:
1. To provide the resources and method for effective control of Emergency of -
Fire and to minimise the damage to property and environment.
Trapping of persons to effect the rescue and treatment of casualties.
Occurrence such as explosion, rupture of operating vessels, failure of equipment or

machinery, either resulting into large scale damage or upset of process.
War emergencies like air-raid, bombing etc.
Natural disaster like flooding.
2. To prevent the emergencies from resulting into disasters. To control and contain the
incident.
3. To minimise the effect of occurrence.
4. To plan for the co-ordination of all efforts to limit the destruction. Personal injury and to
speed up the repair of leakage of dangerous substances.
5. To inform employees, authorities and general public about the risk
assessed, safe
guards provided and the role to be played by each one from the Organisation.
CHAPTER II
IDENTITY OF THE FACTORY:
1.
Full name and address of factory.
MUKAND LIMITED
BELAPUR ROAD,
DIGHE P.O. Kalwe- Dist Thane
2.
3.
Pin : 400 605

022-21727500 / 700
022-25348179
www.mukand.com
Mr. Vinod Shah
Telephone No.
Fax
Website
a) Full name and address of the
occupier.
149, Jain Society, Sion (West),

Bombay 400 022
Telephone No.
022-21727153
Mobile No.
9892330903
b) Full name and address of
Mr. Prakash Pote
Factory Manager
Mukand Limited, Kalwe

Thane 400 605
Telephone No.
022-21727733
Mobile No.
9819210041
4. Manufacturing activities
: We are engaged in manufacturing of wire rods/bars/

flats
(through
Electric
Arc
Furnace
route)
and
material handling & process plant equipments.

5. Surrounding of factory
: There is no school, hospital or any other public

institution
within
Kms.
around
the
factory
premises .
6.
Details of number of employees Shift-wise.
Name of shift
Maximum workers at a time

Male: Female
Explanation
: Total
A) MONTHLY RATED EMPLOYEES:Ist Shift & Genl. Shift
1064
IInd Shift
88
IIIrd Shift
126
= 1278
B) DAILY RATED EMPLOYEES:Ist Shift & Genl. Shift
575
II nd Shift
411
III rd Shift
265
Total
= 1222
____
= 2529
CHAPTER III
HAZARDOUS SUBSTANCES USED / SITUATION IN THE FACTORY
A) Hazardous Substance:
Name of Gas
Max. storage Capacity
Ambient Pressure Storage Tanks
LPG
40 MT
Pressure: 8.5 kg/ cm2 abs at 32 oC
B) Definition of LPG:
Liquefied Petroleum gas is generally known as LPG is the term applied to those
hydrocarbons
which
are
gaseous
in
nature
at
normal
atmospheric
pressure
and
temperature, but may be condensed to the liquid state at normal temperature by the
application of moderate pressure. Although they are used as gases, they are stored,
transported as liquid under pressure.
C) Hazards of LPG:
The properties of LPG which are of direct importance to staff engaged in handling it are
listed below:1. At normal atmospheric temperature and pressure LPG is vapour.
2. LPG vapour is heavier than air and escaped product therefore tends to accumulate in low
lying areas and to flow at ground levels unless dissipated.
3. LPG vapour can be liquefied by compressing it. This change of state generates heat and
the product gets warmer. The greater the pressure, the higher the temperature of
product.
4. When pressure is released and LPG changes to vapour, the change of state requires
heat. This comes from the product itself and forms the surroundings, causing both to
drop in temperature. The product especially when evaporating can become cold enough
to cause frost burns on bare flesh and to condense water vapour from the air.
Condensed water vapour causes a visible white cloud in the vicinity of a link: often
leading to frost / ice formation on the outside of cylinders, pipe lines etc.
5. LPG is stored and transported as a liquid under pressure at ambient temperature.

6. The vapour pressure of LPG is 760 mm Hg at 31.1 F; 1823 mm Hg at 77 F
7. The Boiling Point of LPG is 31.1 F, 42 C respectively.
8. The expansion of LPG when warmed is about 15/20 times greater than of water and
exceeds that of most other general petroleum products. Sufficient ullage space for
expansion of liquid when the temperature rises must therefore be left in all storage /
transport containers.
9. Small quantity of LPG in air is flammable .The percentage of gas in an air/gas mixture
which will burn and which is defined as the flammable or explosive limits are as
follows :Product
LPG
Lower limit
1.5
Higher limit
9.0
10. One volume of liquid LPG will expand to approximately 250 volumes of vapour in free air.
11. LPG liquid is lighter than water and will float on it.
12. LPG has a low viscosity and can leak when other petroleum products normally cannot. It
is also a poor lubricant and leaks therefore likely to occur at pump seals and glands.
13. Although pure LPG is colourless and odourless, the product as marketed in India is
stenched by trace contaminants. The product is odourised sufficiently with Mercaptan for
detection of leak by smell at concentration of 1/5th the lower explosive limit.
14.
LPG -
Vapour pressure is 120 Kg/cm2 at 100 F
(RVP), (SR)
As per Annexure I
D) POSSIBLE ACCIDENT SCENARIOS:

a) Fire and Explosion hazard due to LPG:
Accident Scenario
1.
In
case
of
leak
from
Emergency action
flanges,
Detect the extent of leakage by leak-detect or if
valves, Tail ends or during transfer
lower flammable limit of (i.e. LEL =2 to 10%
from main tank.
v/v), then isolate that branch of line. Stop gas

flow. Extinguish open flames in that area.
Prohibit
smoking;
evacuate
workers,
open
doors and windows for dissipation of leaked

gas. Use water curtain technique to prevent the
cloud traveling to open flame area (Detector is
available with HF, Bell Furnace). Report to
2.
If leaking gas is ignited at the
District Magistrate , Factory Inspector, etc

Estimate the leak rate. See that the
flame
source of leak.
does not impinge on other LPG line or control

instrument. Do not extinguish fire. But post
trained personnel to prevent future spread of
fire. Rush to control valve and stop the gas
flow. Watch flame diminishing. Call Fire brigade
Police,
Mutual
aids
members.
Report
to
magistrate Factory Inspector etc.
3.
Fire near storage tank Farm Area
If fire is beyond main isolation valve (from

tank), follow procedure as in 2 above. If fire is
near farm area, then use water and DCP type
extinguisher to fight fire. Never allow fire to
spread to the area below the tank. Start cooling
the tank by emergency water spray. Call Fire
brigade Police, Mutual aid members Report to
District
magistrate, Factory Inspector etc.
4.
If fire is right under the tank.
If fire is right under the tank or surrounding

LPG lines, valves etc. and if the same does not
come under control within half an hour, then

evacuate all the workers from the factory. Open
tank cooling at full flow, control all rescue
operations from along the line of tank (Not
from dish end side). Call
Fire brigade,
police and of mutual aid & Factory inspector.
5.
If Safety valve blows while fire
Dissipate LPG cloud by water curtain away
continues.
from fire area very carefully to avoid the injury

due to vapour cloud explosion (VCE).
6.
If
Safety
ignited
nozzle.
valve
right
on
discharge
the
gets
Do not try to extinguish the fire at the nozzle.
discharge
Try to keep the tank cool by water spray.

There is no danger, concentrate with full force
to control the fire under the tank. If possible
try to empty the tank by transferring the
contents to another tank.
10
CHAPTER IV
EMERGENCY CONTROL MEASURES:
A) SALIENT DOS AND DONTS FOR LPG:
1) Do not smoke near LPG storage area or usage point.
2) Do not use naked flame in LPG storage yard. Even spark can cause major fire.
3) No unauthorised person is allowed to work on LPG installation or line without a work
permit concerned Zonal Chief.
4) Fire fighting equipments like fire extinguishers and sand buckets must be provided near
LPG installation.
5) Before starting work, gas concentration test work must be got done with the help of
concerned Zonal Chief and written clearance obtained to commence the work.
6)
LPG storage area must be fenced well and lockable door should be provided. Door
should be locked and key should be under control of the Zonal Chief.
11
7) No gas cutting welding should be done in the vicinity. In case it is required to done, all
necessary precautions must be taken so that no fire or explosion takes place.
8) Well trained supervisors must be present on the job site throughout the period of the
execution of jobs.
9) While filing the bullet, vapourisation line must be used.
10)Bullets should be filled up to 80% level only.
11)Trained and authorised person should be present at the time of taking the fill in the
bullets.
B) FIRST AID FACILITIES (In house)

1.
First aid boxes
51 Nos.
2.
Stretchers
4 Nos.
12
3.
First aid team
Factory medical officer -02 nos available in

general shift and One Assistant Medical
Officer available round the clock.
4.
5.
Ambulance
Oxygen cylinders
One No.
Two Nos.
C) EMERGENCY HANDLING FACILITIES (In house)

Fire engine with 7500 litre of water and 1000 litre of foam
Total number of Fire extinguishers:
DCP
249 Nos.
Foam type
91
Nos.
Fire Hydrants
41
Nos.
Trained persons on shop floor are available in all shifts in addition to Security department.
Security department is fully trained to operate fire engine and extinguish all type of fire
which can occur in our factory.
13
No. of vehicles available in each shift.
2 Nos.
(In addition to these, Executives vehicles are available round the clock, as the stay in
colony, approximately 25 cars).
Buses
9 Nos.
14
Chapter V
EMERGENCY ORGANISATION CHART
MANAGING DIRECTOR
DIV HEAD MBD

HEAD MFG
DIV HEAD ADMN.
DIV HEAD KSP
CHAIRMAN PLANT
SAFETY COMMITTEE
DEPT MANAGERS
SUPERVISORS
DEPT MANAGERS
AREA
SAFETY
COMMITTEE
AREA
SAFETY
COMMITTEE
WORKMEN
SUPERVISORS
WORKMEN
SAFETY OFFICERS
OFFICER HOUSEKEEPING
15
CHAPTER - VI
A) EMERGENCY RESPONSE:
Emergency Alarm:
Emergency alarms have been provided at four different locations in the factory area and one
central alarm near canteen. Local alarms are to be actuated by concerned area site
controller and central alarm by security. Depending on the need evacuation shall be
organized by the site controller at 4 assembly points in respective block. There will be a
interrupted alarm (three times up & low, three minuets) to indicate emergency where as for
emergency clearance continuous alarm (three minuets) will be blown.
Emergency control Centre:
The main controlling centre during an emergency is Emergency control centre near New
Ganesh Gate (Ext: 100 / 526).
Assembly point:
The entire factory area has been divided into four blocks. There is one assembly point in
each block and in addition to these four, one main assembly point is declared near Time
office and Security office Ganesh dwar.
Facilities in Emergency Control Centre:
Telephone and Mobile phones of important person, detailed Onsite Emergency plan, list of
first aiders, fire fighters, MSDS of all chemicals and Fire fighting equipment, are provided in
Emergency Control Centre.
CHAPTER VII
EMERGENCY EVACUATION (PROCEDURE & DUTIES)
DUTIES IN CASE OF EMERGENCY:Every individual worker as well as the incident controller, main site controller and other key
personnel are expected to use the best presence of mind and take prompt action to save life
and minimise damage to the plant, property and environment.
16
However following duties are fixed to avoid the chaos: 1) The person who detects the fire/gas leak should not get panicky. He should use common
sense with presence of mind.
2) He should shout and alarm the people in the area.
3) In case of fire, he should reach to the scene of fire and tackle the fire with suitable
extinguisher available near shouting for help simultaneously.
4)
If he is unable to extinguish the fire, he should see that the fire does not spread to
nearby area.
5) In case of gas leak, he should immediately contact, In charge SMS and In Charge TSD,
alternatively Shift In charge SMS and Bell furnace. He should also inform security on
Tel.No.100 / 526 and safety dept. on Tel.No. 412.
6) The Site Controller along with one more officer shall go to the site and after assessing
the gas leak, shall inform to Shri. R. Negi, who is also the Main Site Controller:
a) Place of Fire / gas leak
b) Extent of leakage
c) Actions taken by him , and
d) The material involved.
Action by Incident Controller:
His primary duty is to take full charge of the accident scene and coordinate the actions in
consultations with the site controller.
In absence of the Site Controller, the next in charge person will assume the charge.
Duties of Site Controller:1. Immediately on arrival he will assess the scale of emergency and decide if a major
emergency exists or is likely.
2. He will activate the On-site action plan, depending on the type of emergency.
3. He will instruct the Security Head to report the emergency to Site main controller.
4. Till the arrival of main controller, he will assume the responsibilities of Main controller.
5.
Direct the shutting down of the plant if required and evacuation ensuring the wind
direction. Identify the area likely to be affected by the emergency.
6. Brief the Site Main Controller when he arrives on the scenes.
17
Duties of Main Site Controller:

The Manager (TSD) has been appointed to this post. He will shoulder the overall
responsibilities of the rescue operations. He shall direct all the operations and call the
outside help from Emergency Control Centre.
18
The main duties of Main Site Controller among others include:1. To relieve the Incident controller of responsibility of overall Main Controller of event.
2. Next in consultation with the Incident Controller and the first person he will take stock of
the situation considering :-
The exact place of where the leakage / fire have occurred.
The time for which the leakage / fire has occurred.
Search for the injured and / or casualties.
1) He shall ensure that all the key persons are called on site. He shall delegate any extra
duty to any person depending upon the situation and his judgement.
2) He shall call the members of Mutual aid. (Phone numbers as given).
3) He shall report the event and its extent to the nearest District Police Station, Fire
brigade, Civil Difence Force, District Emergency Officer, Factory Inspectorate and other
voluntary body to assist to the risk.
4) He shall arrange to call the expert from the LPG, Supplier Company. Narrate event and
seek advice on phone. Follow their instruction till their arrival.
5) Advice Fire brigade, Police Mutual Aid Members on specialised technical aspects of the
materials involved rather internal details of the factory.
19
6) Depending upon situation, he shall take decision as to whether to declare major

emergency or not.
7) He shall immediately communicate the decision to the Police and Fire brigade office.
8) He shall advice the police and Fire Brigade about :-
Extent and likely effects of leak / Fire out side the boundary.
Any other important technical advice on the possible effects and measures
etc.
20
Duties of Security Personnel:

In addition to the normal duties of maintaining security at the place of work, they shall
discharge following duties:1) They shall be in-charge of fire fighting and rescue operations with the assistance of
essential workers and key personnel till the arrival of fire brigade and Police. These
operations shall be under the direct supervision of Incident Controller.
2) Brief the Fire brigade crew about the available resource and help them.
3) Restrict and screen the visitors.
4) Raise the main emergency siren
5) Assist the task force team in lifting, shifting of Injured / casualties.
6) Help evacuation if the same is decided by Main Site Controller for major emergency.
7) Act as runners or appoint the persons to act as runners in the event of failure of
communications system.
Key Personnel:
The person acting / assuming
the charge of the following post at the time of emergency
shall act as key personnel to assist the incident and Main Site Controller.
21
In-Charge in each shift of
Steel Melt Shop
Rolling Mills
Maintenance In-Charge of Electrical & Mechanical
Dispensary staff.
Personnel dept. staff
ESSENTIAL WORKERS:
In each shift, there will be available some trained workers in Fire fighting.
It will be task force to assist and execute the instructions of Incident and Main Site
Controller:-
The Maintenance crew
LPG sections officers, staff and workers.
Steel Melts Shop and Mill staff.
CHAPTER - VIII
EMERGENCY HANDLING FACILITIES FOR LPG STATION
1) LPG tanks are provided with spray cooling water system.
2) Hydrant line is provided in LPG tank farm area. Mayura Showers are provided near LPG
tanks. Hydrant line is connected to OHT. The capacity of OHT 400 Cu. M.
3) The Fire extinguishers are provided near enterence gate.
22
4) Sand buckets are provided in LPG farm areas.

Details of Fire Extinguishers:a) LPG yard near Railway Gate :
DCP
1 No.
100
Lbs
DCP
1 No.
25
Lbs
Foam
1 No.
45
Liters
b) LPG yard near STC bldg:

DCP
1 No.
100
Lbs
DCP
1 No.
25
Lbs
Foam
1 No.
45
Liters
5) Fire tender is available round the clock in the company under the control of Security
Dept. which can be called in case of need.
23
CHAPTER - IX
Disaster Management Plan for LPG
Leakage / Fire.
C) About LPG:
Liquefied Petroleum gas is generally known as LPG is the term applied to those
hydrocarbons
which
are
gaseous
in
nature
at
normal
atmospheric
pressure
and
temperature, but may be condensed to the liquid state at normal temperature by the
application of moderate pressure. Although they are used as gases, they are stored,
transported as a liquid under pressure.
D) Properties of LPG:
The properties of LPG which are of direct importance to staff engaged in handling it are
listed below:15. At normal atmospheric temperature and pressure LPG is vapour.
16. LPG vapour is heavier than air and escaped product therefore tends to accumulate in low
lying areas and to flow at ground levels unless dissipated.
17. LPG vapour can be liquefied by compressing it. This change of state generates heat and
the product gets warmer. The greater the pressure, the higher the temperature of
product.
18. When pressure is released and LPG changes to vapour, the change of state requires
heat. This comes from the product itself and from the surroundings, causing both to
drop in temperature. The product especially when evaporating can become cold enough
to cause frost burns on bare flesh and to condense water vapour from the air.
Condensed water vapour causes a visible white cloud in the vicinity of a link: often
leading to frost / ice formation on the outside of cylinders, pipe lines etc.
19. LPG is stored and transported as a liquid under pressure at ambient temperature.
20. The Boiling Point of LPG is 42 C to 0 C depending on percentage mixture of butane
and propane.
21. The expansion of LPG when warmed is about 15/20 times greater than of water and
exceeds that of most other general petroleum products. Sufficient space for expansion of
liquid when the temperature rises must therefore be left in all storage / transport
containers.
24
22. Small quantity of LPG in air is flammable .The percentage of gas in an air/gas mixture
which will burn and it is defined as the flammable or explosive limits are as follows :Product
LPG
Lower limit (%)

1.9
Higher limit (%)

9.0
Flammability limits, also called flammable limits, or explosive limits give the proportion
of combustible gases in a mixture, between which limits this mixture is flammable. Gas
mixtures consisting of combustible, oxidizing, and inert gases are only flammable under
certain conditions.
The lower flammable limit (LFL) (lower explosive limit) describes the leanest mixture that
is still flammable, i.e. the mixture with the smallest fraction of combustible gas, while the
upper flammable limit (UFL) (upper explosive limit) gives the richest flammable mixture.
Increasing the fraction of inert gases in a mixture raises the LFL and decreases UFL.
23. Specific gravity of liquid LPG is 0.49 to 0.57, which is lighter than water. Hence the
liquid LPG float on water.
24. Pure LPG is colourless and odourless, the product as marketed in India is stenched by
trace contaminants. The product is odourised sufficiently with Mercaptan for detection of
leak by smell at concentration of 1/5th the lower explosive limit.
25.
LPG -
Vapour pressure is 120 Kg/cm2 at 100 F.
E) Hazards of LPG storage

a. LPG leakage / Fire
b. Vapor Cloud Explosion An accidental release of flammable liquid or gas, there
is a possibility that it may form a cloud which can spread along the wind
direction, delayed ignition of cloud away from the source of release result in
vapor cloud explosion and associated blast.
c. Boiling liquid expanding vapor explosion (BLEVE) This event may occurs
when a pressurized gas vessel is exposed to heat or fire. Liquid boils due to heat
resulting in high pressure. Vessel ruptured occurs due to overheating and
weakening of the tank surface above liquid level.
(i.e. - If a Pressurized gas vessel (LPG bullet, etc.) is exposed to heat or fire.
The liquid inside the vessel (LPG Bullet, etc.) boils because of heat generates
high pressure. Due to overheating and weakening of the tank surface above
liquid level, vessel gets ruptured and explosion occurs.)
25
26
F) Layout of M/s. Mukand Ltd., Indicating LPG Stations and Assembly Points at various Locations
TBIA Road
Jivan Gate
Assembly Point
MBD Office
LPG
Stor
age
Rail
way
Gate
Assembly Point
Time Office
ECC
Training centre
LPG
Stor
age
New
Land
Assem
bly
Point
PH No.
4
Assem
bly
Point
Bar
Mill
LPG
Stora
ge
Near
Bomb
ay
Oxyg
en
Assembly Point
New Land
27
E) LPG STORAGE DETAILS:
Sr
No
1
Department
a) SMS
b) Bell Furnace
a) STC
b) Hardening
Location
Tank Capacity
(MT)
No of Tank
Near Railway Gate
10
Opposite to TSD
Building.
10
LPG is used as source of energy. As LPG is having a flammable property, there is potential
for fire / explosion at site. Hence the Disaster Management Plan is prepared for the same.
28
LPG TANK FARM AREA SCHEMATIC DIAGRAME - RAILWAY GATE
Water
Pump
Hydrant Point
To
Plant
Water Sprinkler
Hydrant Point
Fire Hose Box
Mayura
Shower
E
N
T
R
A
N
C
E
Mayura
Shower
Gas Detector
Gas Detector
Liquid Line
Unloading Pump
Vaporizers
Vapour Line
DCP
CYLI
DER
S
Gas Detector
Hydrant Point
29
F) EMERGENCY PLAN FOR LPG LEAKGE / FIRE

LOCATION Near Railway Gate
Gas Detection system is installed at LPG Tank farm area at following locations
a) Near Bullet 2No. b) Near vaporiser.
If there is any leakage of LPG, detector sense and blows the alarm located at
Chemical Lab.
A) Chemical Lab Personnel:
After getting alarm of LPG leakage, informs immediately to Incident Controller - I

(Mr. C. J. Jadhav) / Bell Furnace Supervisor at his office 283 or Mobile
9892212135 or Hot line No. *1227.
B) Incident Controller Mr. C J Jadhav:
Informs (by nearest telephone or with mobile from remote place) about the incident
to Main Site Controller (MSC) - Mr. R. Negi) on Extn. 477/ 617 / Mobile
9821721397.
Rush to the emergency site (LPG yard near railway gate) with Bell Furnace
supervisor.
Check the actual location of the LPG leakage / fire with the help of supervisor.
Informs to Main Site Controller about leakage / fire.
Checks the wind direction & start Mayura Shower and Sprinkler system.
Isolates the bullets and line under leakage by closing the valve.
Guides security for spraying water taking care of wind direction
Again checks the LPG Concentration, found below LEL (i.e. 1.9%) & inform to MSC.
C) Main Site Controller R. Negi:
Rush to the emergency control centre.

Inform Security to raise Emergency siren (High / Low pitch 3 times) and reach
the site with Fire Tender, Ambulance on Ext. 100/ 526 /678.
Instructs SMS Electrical Dept. (Mr. Kadri, Extn. 214 / Mobile - 9969810859 ) to raise
the emergency siren (High / Low pitch 3 times) and to switch off the power supply
of LPG yard.
Instructs Administrative Manager (Mr. Dilip Raikar) Ext 428 Mobile 9869037852) to inform Emergency response service (ERS) & Rabale Police Station.
Instructs SMS Shift In-charge / SMS Mechanical Maintenance In-charge / SMS
Electrical In-chagre / Billet Yard In-charge to evacuate the peoples towards assembly
point near Railway Gate and carryout the headcount.
After getting message from IC that, LPG leakage is under control, inform Electrical &
Security to raise All Clear siren (Continuous high pitch).
Again inform to Electrical Eng. to switch on power supply of LPG yard.
D) Security & Fire fighting Mr. Anand Balodhi:
30
Raise the Emergency siren at Ganesh Gate.

Send the Fire Tender and Ambulance at site.
Close all the gates for traffic and allow only Emergency Vehicles.
Control traffic for clear access for Emergency Vehicles.
Cordon off the area and wait for further instructions.
Spraying water taking care of wind direction.
After all clear siren, security removes barricades & returns the Fire Tender.
E) Rescue / First-Aid Team Dr. O. Mourya
Rush to the emergency site with fully equipped Ambulance.

Render the First-Aid if required.
Send the injured to the Hospital if any.
Maintain records of first aid and hospitalization.
F) Engineering Team
a) Electrical
Raise the emergency siren at SMS area.
Switch off the power supply at LPG area
After leakage stopped again raise the ALL CLEAR Siren at SMS area.
b) Mechanical
Arrest the leakage.
G) Shift Incharge SMS- Operation / SMS - Mech Maint / SMS Elec. / Billet Yard
Receives instruction from Main Site Controller and subsequent headcount to be
carried out at assembly point .
On receipt of all clear signal should inform the MSC on headcounts after the situation
is under control.
H) Administration (Mr. Dilip Raikar)
Receives information on incident of LPG Leakage from Main Site controller
Communicates with Emergency Rescue services. (Police / Hospital / Fire Brigade,
etc.)
Communicates with Government Authorities like Directorate of Industrial Safety &
Health.
On receipt of communication from MSC after the situation is under control, he
reverts back to ERS & Govt Authorities accordingly.
31
32
LPG TANK FARM AREA SCHEMATIC DIAGRAME - NEAR BOMBAY OXYGEN
33
G) EMERGENCY PLAN FOR LPG LEAKGE / FIRE

LOCATION Near Bombay Oxygen.
Gas Detection system is installed at LPG Tank farm area at following locations
a) Near Bullet.
b) Near vaporiser.
c) Near Unloading Pump.
If there is any leakage of LPG, detector sense and blows the alarm located at Short Time
Cycle Furnace
A) Short Time Cycle Furnace supervisor :
After getting alarm of LPG leakage, immediately informs to Incident Controller II (Mr. C. J. Jadhav) at his office Ext. No. 477 / 617 or Mobile 9892212135 or
Hot Line - *1227
B) Incident Controller Mr. C. J. Jadhav.
Informs (by nearest telephone or with mobile from remote place) about the incident
to Main Site Controller (MSC) - Mr. R. M. Negi on Extn. Extn.477/ 617 /
Mobile 9821721397
Rush to the emergency site (LPG yard near Bombay Oxygen) with STC Furnace
supervisor.
Check the actual location of the LPG leakage / fire with the help of supervisor.
Informs to Main Site Controller about leakage / fire.
Checks the wind direction & start Mayura Shower and Sprinkler system.
Isolates the bullets and line under leakage by closing the valve.
Guides security for spraying water taking care of wind direction.
Again checks the LPG Concentration, found below LEL (i.e. 1.9%) & inform to MSC.
C) Main Site Controller Mr. R. M. Negi:
Rush to the emergency control centre.

Inform Security to raise Emergency siren (High / Low pitch 3 times) and reach
the site with Fire Tender, Ambulance on Ext. 100 / Mobile-9820771489
Instructs Electrical Dept. (Mr. S C Das, Extn. 397/ Mobile - 9920576482) to raise the
emergency siren (High / Low pitch 3 times) and to switch off the power supply of
LPG yard.
Instructs Administrative Manager (Mr. Dilip Raikar) Ext 428 Mobile 9869037852) to inform Emergency response service (ERS) & Rabale Police
Station.
Instructs BMI Shift Incharge / STC Shift Incharge / TSD Incharge to evacuate the
peoples towards assembly point near Railway Gate and carryout the headcount.
After getting message from IC that, LPG leakage is under control, inform Electrical &
Security to raise All Clear siren (Continuous high pitch).
Again inform to Electrical Eng. to switch on power supply of LPG yard.
D) Security & Fire fighting Mr. Anand Balodhi :
Raise the Emergency siren at Ganesh Gate.

Send the Fire Tender and Ambulance at site.
Close all the gates for traffic and allow only Emergency Vehicles.
Control traffic for clear access for Emergency Vehicles.
34
Cordon off the area and wait for further instructions.

Spraying water taking care of wind direction.
After all clear siren, security removes barricades & returns the Fire Tender.
E) Rescue / First-Aid Team Dr. Omraj Mourya:
Rush to the emergency site with fully equipped Ambulance.

Render the First-Aid if required.
Send the injured to the Hospital if any.
Maintain records of first aid and hospitalization.
F) Engineering Team Mr. S. C. Das:
a) Electrical
Raise the emergency siren at Bar Mill Inspection area.
Switch off the power supply at LPG area
After leakage stopped again raise the ALL CLEAR Siren at SMS area.
b) Mechanical
Arrest the leakage.
G) Shift Incharge BMI Shift Incharge / STC Shift Incharge / TSD shift Incharge
Receives instruction from Main Site Controller and subsequent headcount to be
carried out at assembly point near time office.
On receipt of all clear signal should inform the MSC on headcounts after the
situation is under control.
H) Administration Mr. Dilip Raikar:
Receives information on incident of LPG Leakage from Main Site controller
Communicates with Emergency Rescue services. (Police / Hospital / Fire Brigade,
Member of Mutual Aid Response Group, etc.)
Communicates with Government Authorities like Directorate of Industrial Safety &
Health.
On receipt of communication from MSC after the situation is under control, he
reverts back to ERS & Govt Authorities accordingly.
OTHER POTENSIAL EMERGENCIES

A) GAS CUTTING /HANDLING & STORAGE OF GAS (OXYGEN, DA, LPG)
a)
The person who discovers the fire / leakages shall immediately inform Fire &
Security Dept. (Extn. 100 / 372 / 678 / 526) for sending Fire Tender along
with fire fighters.
b)
Zonal Chief or shift supervisor shall inform dispensary for sending

ambulance to the site with doctor & attendant.
c)
If possible try to shift the cylinder in open place. Further he should try to
cool cylinder body with water.
35
B)
d)
In case of fire person who is/are trained for fire fighting shall try to
extinguish the fire with proper extinguisher after clear identification of type
of fire & its severity. If the severity of fire is major, local fire fighters should
wait till Fire & Security personnel reach to the site.
e)
Fire & Security team after reaching to the site along with fire tender, shall
first get the detail information regarding place of fire, severity of fire &
persons trapped inside the room/building & start fire fighting & rescue
operations accordingly with the help of Breathing Apparatus, Fire Suit, etc.
f)
Medical Officer / Assistant Medical Officer shall reach to the site along with
fully equipped ambulance for providing first aid to the injured persons if
any.
g)
If any trained First Aider is present in the section then he may also
accompany Doctors for helping them.
h)
Security Dept. shall control the traffic as well as crowd if required.
i)
After extinguishing the fire, collect the debris in a separate container and
send for disposal in the secured pit near SMS side ETP as a hazardous
waste.
j)
The water accumulated in the area after extinguishing the fire, to be

collected in a separate drum / container / tanker and to be sent to ETP for
further treatment and disposal.
k)
The concerned department head along with Fire squad shall ensure the
actions mentioned in (i) and (j).
LEAKAGE / OVERFLOWING / FIRE IN STORAGE, TRANSPORT, HANDLING OF

FUEL OIL & LUBRICANTS
I) Leakage / Overflowing:
a) The person who discovers the leakage / over flowing of fuel oil / lubricants
shall immediately inform to concerned departmental head / representative.
b) If he is familiar with the process should try to stop leakage / overflowing by
closing valve / putting OFF the pumping motor.
c) The departmental head / his representative should inform
department for sending fire tender. He should then rush to the site.
security
d) The departmental head / his representative shall make efforts to contain the
leakage / over flowing of oil / lubricants by using suitable media e.g. sand,
saw dust, gunny bags etc.
e) The departmental head / his representative shall take suitable action to stop
leakages / overflowing of Oil / Lubricants.
f) The leaked / spilled oil / lubricants shall be collected in a separate container
and shall be sent to disposal yard.
36
g) The material used for containment of leakage / overflowing shall be disposed

as hazardous waste.
h)
In case of major leak from pipelines follow the same steps as mentioned
above.
i)
The security fire squad shall follow the instructions from departmental head /
his representative control the situation.
II) Fire Emergency:

a)
The person who discovers the fire shall immediately inform Fire & Security
Dept. (Extn. 100/372/678 / 526) for sending Fire Tender along with fire
fighters.
b)

c)
d)
f)
any.
g)
If any trained First Aider is present in the section then he may also
h)
Security Dept. shall control the traffic as well as crowd if required.
i)
If any electrical installations / cables are in the vicinity of the fire, ensure
power supply to such installations is switched off by informing the
concerned electrical personnel.
j)
Switch off all the FO / LDO handling pumps and close all the valves in the
circuit.
k)
send for disposal in the secured pit near SMS side ETP as a hazardous
waste.
l)
The water accumulated in the area after extinguishing the fire, to be

m)
The concerned department head along with Fire squad shall ensure the
actions mentioned in (k) and (l).
37
C ) STORAGE & TRANSPORT OF COMPRESSED AIR

a. Incase of explosion of compressor receiver (Inbuilt), inform concerned persons
immediately. (Security & Medical units), switch off compressor & isolate the
particular compressor. Inform all concerned, handling pneumatic operated valves
about the failure of compressor (E.g. : Emergency valves will open when air is
stopped, control valves will not operate).
D.
STORAGE OF USED OIL FIRE HAZARD
I) Leakage / Overflowing:
a) The person who discovers the leakage / over flowing of fuel oil / lubricants
shall immediately inform to concerned departmental head / representative.
b) If he is familiar with the process should try to stop leakage / overflowing by
c) The departmental head / his representative should inform
department for sending fire tender. He should then rush to the site.
security
d) The departmental head / his representative shall make efforts to contain the
leakage / over flowing of oil / lubricants by using suitable media e.g. sand,
saw dust, gunny bags etc.
e) The departmental head / his representative shall take suitable action to stop
leakages / overflowing of Oil / Lubricants.
f) The leaked / spilled oil / lubricants shall be collected in a separate container
and shall be sent to disposal yard.
g) The material used for containment of leakage / overflowing shall be disposed
as hazardous waste.
h)
In case of major leak from pipelines follow the same steps as mentioned
above.
i)
The security fire squad shall follow the instructions from departmental head /
his representative control the situation
Fire Emergency:
a)
Dept. (Extn. 100/372/678/526) for sending Fire Tender along with fire
fighters.
b)

c)
d)
38
f)
any.
g) If any trained First Aider is present in the section then he may also
h) Security Dept. shall control the traffic as well as crowd if required.
i)
power supply to such installations is switched off by informing the concerned
electrical personnel.
j)
send for disposal in the secured pit near SMS side ETP as a hazardous waste.
k) The water accumulated in the area after extinguishing the fire, to be

F.
LEAKAGE IN STORAGE & TRANSPORT OF CHEMICALS (ACIDS / ALKALIS) HEALTH HAZARD

a) The person who discovers the leakages / spillages / bursting of the tank /
storage container shall immediately inform Zonal Chief or shift supervisor &
Fire & Security Dept. (Extn. 100/372/678/526) for sending Fire Tender along
with fire fighters.
b) Zonal Chief or shift supervisor shall inform dispensary for sending ambulance
to the site with doctor & attendant.
c) Try to control the spillage from tank / container. Try to contain the spilled
material by using sand or other suitable material.
d) If the fumes are generating from spilled chemical, evacuate all peoples in the
surrounding area. Zonal In charge should organize to neutralize the acid with
basic. In Case of basic, wash with water.
e) Collect all spilled material in equalization Tank and give treatment before
disposal
f) Use Cartridge type fume face mask, safety shoes, hand gloves while handling
spilled material.
g) Refer the MSDS for in case of exposure to spilled material.
h) After taking all corrective action restore normal operation.
39
G)
ELECTRICAL FIRE ( Short circuit, transformer burst , panel fire etc):

a)
Dept. (Extn. 100/372/678/526) for sending Fire Tender along with fire
fighters.
b)
He should try to switch off power supply to that area & inform electrical in
charge / electrical shift in-charge
c)
extinguish the fire with DCP / CO2 extinguisher. Avoid use of foam type
extinguisher / water if power supply is ON. If the severity of fire is major,
evacuate the people working in the area . Local fire fighters should wait till
Fire & Security personnel reach to the site.
d)
first get the detail information regarding place of fire, severity of fire start
fire fighting & rescue operations accordingly with the help of Breathing
Apparatus, Fire Suit, etc.
f)
any.
g) If any trained First Aider is present in the section then he may also
h) Security Dept. shall control the traffic as well as crowd if required.
i)
power supply to such installations is switched off by informing the concerned
electrical personnel.
j)
send for disposal in the secured pit near SMS side ETP as a hazardous waste.
k) The water accumulated in the area after extinguishing the fire, to be

H) OVERFLOWING OF EFFLUENT WATER IN THE STORM WATER DRAIN
a) The person who discovers the over flowing of effluent in the storm water
drain shall immediately inform to concerned departmental head /
representative.
b) If he is familiar with the process should try to stop overflowing of effluent by
c) The departmental head / his representative should inform Administration /
security department for taking necessary action to avoid flowing of effluent
to outside the factory premises.
d) The Administration / security department shall close the gate valve provided
at the exit point of the storm water drain.
40
e)
I)
The Administration / security department shall make necessary arrangement

for collecting the over flowed effluent in to tanker / container and dispose it
off to the ETP.
NON FUNCTIONING OF ETP:

a) In situation of non functioning of ETP, the ETP operator shall immediately
inform to his departmental head / shit in charge.
b) Till ETP put in operation the departmental head / shit in charge shall explore
the following possibilities i) If possible, store the incoming effluent , ii)
Arrange the transfer of effluent by using tanker to other ETP available inside
the factory premises, iii) Discuss with CETP authorities for accepting the
effluent for disposal. If they give the consent, make the arrangement to send
the effluent to CETP.
c) If none of the above is feasible then, the decision on controlling the plant
operations shall be taken in consultation with Divisional Head / Concerned
departmental head.
d) In any case no effluent should disposed off without treatment.
e) The ETP In charge shall take necessary steps for putting ETP in operation
with the help of maintenance department.
J) FAILURE OF FED DURING UHPF / CONVERTER OPERATION

a) Failure of ID fan will be detected through control panel located inside melter
cabin
b) After detection, the FED operator shall inform SMS UHPF & Converter shift
in-charge immediately
c) The power of UHPF & Converter oxygen lancing shall automatically cut off.
d) The FED operator shall Inform maintenance shift in-charge & Chief Engineer
(maintenance)
e) Maintenance shift engineer to arrange and deploy manpower on priority for
rectification of problem.
f) After rectification of problem, inform SMS UHPF & Converter shift in-charge
to restore their operation.
41
K) FAILURE OF CFD SCRUBBER SYSTEM :

a. In case of failure of FES, by pass line of other system must be put in
operation
b. Cover the tanks with HDPE sheet when not in use.
c. Drain the used process tank within the process limit.
d. In case of abnormal fumes observed during pickling operation, remove the
coils from process tank to avoid fume generation and accumulation in the
process area.
e. In case of sudden power failure, use DG set to remove the coils from process
tank to avoid fume generation and accumulation in the process area
f.
In case of abnormal fume emission, evacuate the people working in the area
to the assembly point.
g. Inform the maintenance immediately for putting system in operation.
L) TANKER OVERTRUN (LPG/OIL/ACID) :

a. In case of overturn of tanker inside plant premises carrying LPG/ OILS/ACID
the driver / cleaner/ any person who first notices the incident, shall
immediately inform to the security.
b. The security in charge along with his team shall immediately rush to incident
site along with fire tender.
c. The security In charge shall immediately inform to Main Site Controller /
Safety Incharge / concerned plant in charge.
d. The security in charge shall barricade the area to control traffic movement.
e. The Main Site Controller shall immediately report to the Emergency control
centre and shall assess the situation in consultation with the Incident
Controller and security in charge.
f.
The main site controller after assessing the situation shall instruct to raise
the emergency siren to evacuate the people to the assembly point.
g. The concerned plant in charge shall reach to the site and act as an Incident
controller. He shall take stock of the situation and inform the main site
controller.
h. In case of leakage of LPG leakage from the tanker, the main site controller
shall immediately contact the supplier company for immediate assistance and
if required get additional fire tenders from outside
42
i.
In case of LPG is leaking from tanker, the incident controller shall direct the
fire squad to spray water on tanker to cool the tanker.
j.
The security shall try to contain the spillage by using the sand / saw dust/
any suitable material like mill scales etc.
k. In case of leakage of Acids / oil, the incident controller shall arrange to

transfer material inside tanker which is overturned. Where as in case of LPG
tanker, the team of authorized supplier shall do the same job.
l.
When leakage is under control / transfer of material is completed, the

incident controller shall arrange to collect spilled material. If it is oil, collected
material along with material used for containment, shall be collected in
separate container and sent to disposal yard for disposal as hazardous waste.
In case of Acid, collect the spilled acid along with the material used for
containment in the separate container and transfer it to the CFD
neutralization tank for further treatment. Where as in case of spilled LPG,
actions to be taken as advised by the authorized supplier.
m. The spilled water used for cooling tanker / fire fighting shall be collected
separately in the tanker / container and shall be disposed to nearest ETP.
n. After completion of above actions, the incident controller shall inform main
site controller about the situation. The main site controller shall raise All
Clear siren.
43
CHAPTER X
EMERGENCY MUTUAL AID
Mutual aid Members:1)
M/s
National Organic Chemical Industries
Tel No.
27692461& 27692471
Telex
Tel No.
011-82465
27692381/85
Telex
Tel No.
011 - 77005
27600401
Telex
Tel No.
013 12202
27600900/01
Tel No.
276301741/43
Tel No.
27670070 / 27660071 /
Tel No.
27672008
27670104/ 27661062
Ltd, Thane Belapur Road, Thane

2)
M/s
Siemens India
Kalwe Works, Thane Belapur Road, Thane.

3)
M/s
Bharat Bijlee Ltd.
4)
Thane Belapur Road. Thane

M/s Philips India Ltd.
3-TTC, MIDC Indl. Area,
Thane Belapur Road,
5)
Navi Mumbai
M/s Savita Chemicals Ltd.
17-A, TTC, MIDC indl. area, Thane Belapur
Road,
Navi Mumbai
Name of LPG suppliers:1)

2)
Bharat Petroleum Corporation Ltd.

Hindustan Petro. Corporation Ltd.
CHAPTER XI
COMMITMENT OF REHEARSAL AND REVISION
Emergency Mock drill is carried out minimum twice in a year for LPG leakage scenario.
The records of mock drills are maintained in the safety department.
After each mock drill, the feed back from all observers is obtained and necessary actions
are taken by respective departments,
HAPTER XIII
44
EMERGENCY TELEPHONE NOS.

Police
MIDC Rabale
Kalwe
Rabale
Thane Control
27692519
25347233
27692455
25442121 & 25442828
Fire Brigade
Thane
Vashi
25331600
27660101
Thane Municipal Emergency control centre

Emergency response station
Civil Defense
Hospital
Chatrapati Shivaji Hospital

Prakriti
Siddhi
Drishti
ESI Hospital (Thane)
ESI Hospital (Mulund)
1077 (Toll free number from mobile

& landline)
27680208
25342288
022- 25347784 / 25347785/86
25400438
022- 25478555
022- 25392424 / 9867209307
022-25821316, 25823434
022-25645520
Pollution Control Board, Thane Office
25821256, 25829582, 25802272
Collector, Thane
25344041, 25343636, 25344213
Directorate of Indl. Safety & Health (DISH) office ,

Thane
Thane Belapur Inds. Association.(TBIA)
2582 1281
Important MARG
Members
M/s Siemens (Mr. Rao )

M/s NOCIL (Mr. Parvtikar)
27692381 / 85
27692461 / 71
M.S.E.B.
Airoli
2769 2256 , 2769 2240
2769 1919 & 2768 2169
Emergency Contact Persons & Contact Numbers in MUKAND

Sr.
Dept
Responsible Dept.
Responsible person
Ext. No
Mobile No.
45
No.
1
SMS
while emergency
SMS - Operation
SMS- Electrical
Maintenance
Mech. Maint.
WRM
WRM Operation
WRM Elec. Maint
BLM
WRM - Mech. Maint

BLM Operation
BLM Elec. Maint
BM
BLM - Mech. Maint

BM Operation
BM Elec. Maint
TSD
BM-Mech. Maint
TSD Operation
BBD
BM Elec. Maint
BM-Mech. Maint
Production
M/M
CFD
Production
E/M
CPP
Operation
while emergency
Mr. D. N. Patankar
Mr. R. K. Aiyer
Mr. J. T. Ganatra
Mr. Nitin Shah
Mr. S. K. Kadri
Mr. S. B. Gaonkar
Mr. V. M. Joshi
Mr. P. C. Kothary
Mr. P. S. Roy
Mr. S. P. Gaonkar
Mr. M. J. Khare
Mr. D. N. Jagtap
Mr. Prasad Menon
Mr. S B Gite
Mr. J. T. Ganatra
Mr. H. Barhate
Mr. M. V. Bhamare
Mr. Sunil Chaudhary
Mr. Prasad Menon
Mr. Saeed Khan
Mr. Zameer Khan
Mr. H. B. Ghadge
Mr. J T. Ganatra
Mr. S C Das
Mr. Manish Burande
Mr. Sunil Chaudhary
Mr. Prasad Menon
Mr. Saeed Khan
Mr. Zameer Khan
Mr. Diwakar Naik
Mr. J T. Ganatra
Mr. S. C. Das
Mr. Sunil Chaudhary
Mr. A. Chateerjee
Mr. R. M. Negi
Mr. C. J. Jadhav
210
329
325
162
214
214
214
422
324
324
324
239
218
387
325
315
452
127
218
443
273
485
325
388
388
127
218
443
273
443
325
388
127
215
617
408
9322664898
9833980845
9967065851
9892520335
9969810859
9920654958
9819331321
9967579995
9324173034
9869866687
9820380794
9890515961
9987344880
9421909398
9967065851
9833302940
9967730449
9821174935
9987344880
9172308229
9220599027
9987419038
9967065851
9920576482
9967316437
9821174935
9987344880
9172308229
9220599027
9869132432
9967065851
9920576482
9821174935
9322120837
9821721397
9892212135
Mr. S. C. Das
Mr. Sunil Chaudhary
Mr. V. Venkatesh
Mr. S. R. Nair
Mr. S. Ghangurde
388
127
304
509
139
9920576482
9821174935
9322664899
9833805573
9320810036
Mr. S. V. Panse
Mr. N. Laxminarayan
Mr. P. M. Raut
Mr. Junaid Sheikh
399
165
482
188
9967589473
9892013540
9324024101
9322539332
Mr. Vinay Kumar

Mr. P. C. Kothary
Mr. S. S. Bhor
326
422
178
9322664903
9967579995
9867387099
46
MBD
Operation
E/M
10
ADM.
& SEC.
Adm. & Security
11
CONT.
Contracts
12
SAFET
Y
Safety
13
ER
Employee Relations
14
HRD
15
DISP.
Human Resource
Development
Dispensary
16
CE
Chief Executive
(Steel Plant)
Chief Executive
(MBD)
Mr. Balakrishnan
Mr. D D Salunke
Mr. V. M Shah
Mr. G V Ratnam
Mr. J M Sawant
334
246
102
741
124
9869449799
9833251909
9869263639
9969131905
9869053678
Col. N. Ramanan
Mr. Dilip Raikar
Mr. Anand Balodhi
Ganesh Gate
Jeevan Gate
Railway Gate
370
428
678
372
374
373
9324283282
9969037852
9769889201
-------
FIRE TENDER /
Emergency Control
Centre (ECC)
100
---
Mr. Arun Pise

Mr. Rejikumar
753
531
9967622880
9920599212
Mr. P. C. Kothary
Mr. B. K. Mitra
Mr. Sanjay M Thakur
Mr. Maloji Patil
Mr. Ramchandra
Kalke
Mr. Anil Bhadane
Mr. Prakash Pote
Mr. Amar Shinde
Mr. Ashish Shastri
422
238
412
412
412
412
9967579995
9987476923
8805023036
9702942220
9820940102
9022777018
733
311
692
9819210041
9870086824
9820070405
Dr. Omraj Mourya

Dr. A. M. Kulkarni
Dr. K. C. Kulkarni
Dr. A. Verma
Dr. M. Bhagat
Mr. A. M. Kulkarni
555
268
268
268
268
588
9821460641
9869235504
9869734246
7738167054
9867035387
9967589472/
9967006322
Mr. R. Jagannathan
582
9323395235/
9769486337
47

3.05A - Onsite Emergency Plan - Rev 10 - 2013

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ON SITE EMERGENCY PLAN

10th January, 2013

ON SITE EMERGENCY PLAN

HAZARDOUS SUBSTANCES USED / SITUATION IN THE FACTORY

EMERGENCY CONTROL MEASURES

SALIENT DOS & DONTS

EMERGENCY ORGANISATION CHART

EMERGENCY CONTROL CENTRE

PROCEDURES AND DUTIES

EMERGENCY HANDLING FACILITIES FOR LPG STATION

Disaster Management Plant for LPG leakage / Fire

EMERGENCY MUTUAL AID

COMMITMENT OF REHEARSAL & REVISION

DATE OF MOCK DRILLS

IMPORTANT TELEPHONE NUMBERS

Fire and to minimise the damage to property and environment.

Trapping of persons to effect the rescue and treatment of casualties.

Occurrence such as explosion, rupture of operating vessels, failure of equipment or

War emergencies like air-raid, bombing etc.

Natural disaster like flooding.

Full name and address of factory.

Pin : 400 605

149, Jain Society, Sion (West),

b) Full name and address of

Mr. Prakash Pote

Mukand Limited, Kalwe

: We are engaged in manufacturing of wire rods/bars/

material handling & process plant equipments.

: There is no school, hospital or any other public

Details of number of employees Shift-wise.

Maximum workers at a time

A) MONTHLY RATED EMPLOYEES:Ist Shift & Genl. Shift

B) DAILY RATED EMPLOYEES:Ist Shift & Genl. Shift

Max. storage Capacity

Ambient Pressure Storage Tanks

Pressure: 8.5 kg/ cm2 abs at 32 oC

5. LPG is stored and transported as a liquid under pressure at ambient temperature.

Vapour pressure is 120 Kg/cm2 at 100 F

D) POSSIBLE ACCIDENT SCENARIOS:

Detect the extent of leakage by leak-detect or if

valves, Tail ends or during transfer

lower flammable limit of (i.e. LEL =2 to 10%

from main tank.

v/v), then isolate that branch of line. Stop gas

doors and windows for dissipation of leaked

If leaking gas is ignited at the

District Magistrate , Factory Inspector, etc

does not impinge on other LPG line or control

magistrate Factory Inspector etc.

Fire near storage tank Farm Area

If fire is beyond main isolation valve (from

If fire is right under the tank.

If fire is right under the tank or surrounding

come under control within half an hour, then

police and of mutual aid & Factory inspector.

If Safety valve blows while fire

Dissipate LPG cloud by water curtain away

from fire area very carefully to avoid the injury

Do not try to extinguish the fire at the nozzle.

Try to keep the tank cool by water spray.

B) FIRST AID FACILITIES (In house)

First aid boxes