Documenti di Didattica
Documenti di Professioni
Documenti di Cultura
OF
M/s Malbros International Pvt. Ltd.,
Village-Mansoorwal, Tehsil-Zira, Faridkot Road, District-
Ferozepur, Punjab, India. Pin-142047
2016
-------Prepared By------
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Annexure – 8 - On-site Emergency Plan
TABLE OF CONTENTS
Sr. No.
Desciption Page No.
1. Introduction 05
2. Profile of The Company 07
3. General Information of Plant 10
4. Technical Features of Plant 13
5. Effluent Handling Section 17
6. Terminologies Related to Hazards 20
7. Different Phases of Disaster 23
8. Scope , Intent And Objective of Plan 24
9. Classification & Description of Emergencies 26
10. Emergency Mitigation & Preparedness 35
11. Emergency Response Procedures And Measures 37
12. Roles And Responsibilities 40
13. Fire Protection System & Sops 47
14 Communications Services & Infrastructure 54
i. Communication Flow Chart 54
ii. Flow of Information 55
iii. Siren Codes 56
iv. Details of the Emergency Control Centre (ECC) 56
v. Assembly Point and Their Area Coordinator 57
vi. Declaration of on-site and off–site emergencies 58
vii. Medical Facilities 58
viii. Evacuation 60
ix. Information to Public 60
x. Reporting of the Incident 60
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LIST OF ANNEXXURES
Annexxure-A : Material Safety Data Sheets of Hydrochloric Acid
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1. INTRODUCTION
The adoption of new technologies has worked marvels for industry, while consumer
has been benefited from this commercial boom; the nation has also been able to set
a brisk pace of industrial growth. This augurs well for everyone. However, there is a
need to be cautious in dealing with these technological changes. If not handled
properly, they can create several environmental problems: contamination of water
resources, coal and ash dust, mist, particulate etc. Atmospheric changes as well as
loss of precious plant and animal life. These hazards also endanger human life.
Chemicals which are hazardous like Acids, Liquid Ammonia, HCL, H2SO4& Alum
materials which are inflammable like Lubricating and Servo Oil, Rice Husk, Light
Diesel Oil are being more widely used in distillery plants. Improper handling of
these materials, may lead to uncontrollable hazards, costly accidents and in rare
cases may lead to disasters.
In the wake of such disasters, legislation has been enacted to tighten safety norms.
But there is still scope for system failures. In order to generate emergency plan,
each part / section of the plant of the complete plant as a whole need to be studied
and analyzed critically from safety point of view. To control effectively the rise of
such situations, it is imperative to plan “ON –SITE EMERGENCY PLAN”.
After the incident of Bhopal gas disaster and supreme court directions in case
of M/S. Sriram Foods and Fertilizers, the Govt. of India has made some important
amendments to the Factories Act 1948 in the year 1987 with incorporation of
special provisions relating to hazardous process and a new chapter i.e. Chapter IVA
under which the provisions like sections 41A, 41B, 41C, 41D, 41E, 41G & 41H
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covering all hazardous process industries are added. Under the provision of Section
41-B (4) every occupier shall with the approval of the Chief Inspector of Factories
draw up an On-site Emergency Plan and detailed disaster control measures for his
factory and make known to the workers employed therein and to the general public
living in the vicinity of the factory the safety measures required to be taken in the
event of an accident taking place. This is the statutory provision laid down in the act
for preparation of On-site Emergency Plan to control disaster in the factories. Any
accidents may cause emergency and it may lead to disaster, which may cause heavy
damage to plant, property, harm to person and create adverse affects on production.
The manufacturing process carried out in M/s Malbros International Pvt. Ltd.,
Village-Mansoorwal, Tehsil-Zira, Faridkot Road, District-Ferozepur, Punjab,
India comes under the category of Hazardous Process at Item Number 12 as
“Fermentation Industries (Distilleries and Breweries)” in The First Schedule made
under the Section 2 (cb) of the Factories Act, 1948. The need of the onsite
emergency plan was felt due to the statutory requirement as applicable to the
hazardous process under different legislations by State as well Central
Governments. This Onsite Emergency plan is made to comply with the Section 41-
B(4) of the Factories Act, 1948 as applicable to this plant.
Although the similar provisions regarding onsite emergency plan also exists under
Rule 13 of the Punjab Control of industrial Major Accident Hazards Rules, 1993
and Rule 13 of Manufacture, Storage and Import of Hazardous Chemicals Rules,
1989 but these rules are only applicable to MAH units which derive this designation
if they store or process some threshold quantities of different chemicals as specified
in schedules annexed to PCIMAH Rules-1993 & MSIHC Rules-1989.
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Pride of Indian liquors, „The Oasis Group of Companies‟ was incepted in the year
1987. Since then the Oasis Group is growing by leaps and bounds operating in the
field of Distilleries and Breweries. The Oasis Group has a turnover of Rs. 1500
crores in 2014-15 and targets to achieve Rs. 2000 crores by the next financial year.
The Oasis Group presently operates 5 distilleries across the country with a
collective production of approximately 20 crores litres of Grain Based Extra Neutral
Alcohol, making it one of the largest Grain Spirit producers in the Country.
The Group enjoys a very important position amongst the liquor companies in
Punjab by virtue of owning two „State-of-the-Art‟ Grain Distilleries at Ferozepur
and Bhatinda and a bottling unit at Sandhe Hasham-Ferozepur, further
complemented with substantial wholesale and retail outlets which has helped the
Group cover the complete channel of liquor distribution thereby making it a major
player in Punjab.
Oasis Group is a significant player amongst the emerging Indian spirits market with
their International Quality Grain based spirits, Indian Made Foreign Liquor with
consistency of quality, delivery, superior consumer experience, thereby creating
maximum value amongst its connoisseurs.
With the introduction of its Premium Whisky-Blue Patrol, an Imported Vatted Malt
Scotch blend this year, the Oasis Group stands firm with yet another launch of
Super Premium Whisky with dynamic Packaging and blend by next year. The Oasis
Group now plans to broaden its brand base by entering into Semi premium &
Premium Segments in Whisky, Brandy and White Spirits.
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which caters to the Esteemed Indian Armed Forces, the Oasis Group enjoys an
absolute PAN India presence for its IMFL brands.
The Oasis Group provides different varieties of whiskey, vodka, rums scotch etc.
The Oasis Group supports old age homes, hospitals etc.
The Oasis Group has already launched a Pure Herbal Diet Whisky which is blended
out of Aloe Vera, Ginseng & Garcinia. The Oasis Group hopes to project this blend
as a health conscious Whisky.
The group is in the process of launching a tripled distilled Green Apple and Orange
flavored Vodka in the Premium Segment shortly, besides a Premium Grapes Spirit
Brandy for the South Indian market.
Oasis Group is the leading group having five state of the art distilleries in India that
produces Extra Neutral Alcohol (ENA) from grain. The Oasis Group presently
operates 5 distilleries across the country with a collective production of
approximately 18 crores litres of Grain Based Extra Neutral Alcohol, making it one
of the largest Grain Spirit producers in the Country.
Oasis Group boasts of providing the finest quality of ENA that is formulated as per
industrial norms and standards. The Oasis Group also exports Extra Neutral
Alcohol in different parts of the world.
Oasis Group is one of the largest IMFL (Indian Made Foreign Liquor) producers in
the country. It is a significant player amongst the emerging Indian spirits market
with its International Quality Grain based spirits, Indian Made Foreign Liquor with
consistency of quality, delivery, superior consumer experience, thereby creating
maximum value amongst its connoisseurs. Oasis Group is first of its kind in the
country which has sophisticated in-house facilities to produce molasses and non-
molasses based neutral spirits from completely automated Distillation Plants.
Oasis group is the top manufacturer of producing Country Liquor in India with a
sizeable market share. It aims to provide premium quality Country liquor to an
ordinary man, who savors its taste, at the most reasonable rate, Oasis Group aims to
create a stronghold in the country liquor market and intends to extend the depth of
supply coverage for reaching untapped markets and pursue growth by increasing
their penetration in more states and setting up more production units in other
locations. Oasis Group has almost track record of manufacturing quality ethanol,
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extra neutral alcohol and producing quality ethanol, rectified spirits, extra neutral
alcohol and potable country liquor.
Oasis Group specializes in making Distillers Dried Grain Soluble (DDGS), which is
a cereal by product of the ENA production process. The Oasis Group is one of the
largest producers of high nutrient DDGS in India with protein content of minimum
45%. DDGS is an excellent feed ingredient for livestock and poultry diets.
Oasis DDGS are highly digestible, increases efficiency, enhances palatability and
lowers toxicity. Our state-of-the-art distilleries are completely compliant with top-
notch quality norms. Moreover, great care is taken to maintain international
standards of hygiene and handling.
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The Unit is self-sufficient in meeting the fuel and power requirement by way of
backward integration of utilizing its effluent for generating the bio-gas which, in
turn, is utilized for generating the steam and power for its captive requirement.MIL
Distillery also manufactures various brands of IMFL and Country Liquor.
In dry milling, the entire starchy grain is first ground into flour, referred to in the
industry as “meal,” and processed without separating out the various component
parts of the grain. The meal is slurried with water to form a “mash.” Enzymes are
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added to the mash to convert the starch to dextrose, a simple sugar. Ammonia is
added for pH control and as a nutrient to the yeast.
The fermentation process generally takes about 40–50 hours. During this part of the
process, the mash is agitated and kept cool to facilitate the activity of the yeast.
After fermentation, the resulting “beer” is transferred to distillation columns where
the ethanol is separated from the remaining “stillage.” The ethanol is concentrated
to 190 proof using conventional distillation and then is dehydrated to approximately
200 proof in a molecular sieve system.
The stillage is sent through a centrifuge that separates the coarse grain from the
solubles. The solubles are then concentrated to about 30 percent solids by
evaporation, resulting in Condensed Distillers Solubles (CDS) or “syrup.” The
coarse grain and the syrup are then dried together to produce Dried Distillers Grains
with Solubles (DDGS), a high quality, nutritious livestock feed. The CO2 released
during fermentation is captured and sold for use in carbonating soft drinks and
beverages and manufacturing dry ice.
REGISTRED OFFICE:
Oasis group of companies
HD-8, Pitampura, Near Madhuban Chowk,
New Delhi - 110026, India
Phone:+91 - 011-27312685, 011-25229720,
011-25229721Fax: 011-27317765
Cell:+91 - 9899450255, 9873900090
Email: info@oasisgrp.in
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Working Hours:
(General Shift With lunch break from 1.00PM to 2.00PM and 30 Minutes by
rotation in other regular shifts)
Weekly Holiday for Shift: Any one of the week day during the Week
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1. Grain Storage:
Grains are procured from various sources, such as FCI Storage godowns through
agencies and are unloaded into large Storage Silos after Pre-Cleaning. Storage Silos
are specially designed to keep the Grains in good condition for longer durations and
also avoid its deterioration and theft, etc. It is being proposed to have 30 – 45 days
of Grain Storage facility in the Distillery.
The slurry is continuously pumped to a steam jet cooker where high-pressure steam
rapidly raises the slurry temperature. The mixture of slurry and steam is then passed
through the Retention Vessel. The retention vessel has sufficient capacity to provide
the desired retention time at a given flow rate. The cooked mash is discharged to a
Flash Tank. The cooking process, accomplished in the above manner, converts the
slurry into a hydrated, sterilized suspension and is therefore susceptible to enzyme
attack for liquefaction. The gelatinized mash from the Flash Tank is liquefied in the
Final Liquefaction Tank where liquefying enzyme (alpha-amylase) is added. The
liquefied mash is cooled in Mash Cooler and transferred to Saccharification cum
fermentation section. This process initiates the formation of sugar. The gelatinized
mash from the Flash Tank is liquefied in the Final Liquefaction Tank where
liquefying enzyme (alpha-amylase) is added. The liquefied mash is cooled in Mash
Cooler and transferred to Saccharification cum Fermentation section.
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6. Ethanol Distillation:
Fermented wash from wash holding tank T-01 is pumped by wash feed pump P-01
to the top of degassing column (C-2) after preheating the same in beer heater E-02
and spent wash heat exchanger E-01. The vapors along with non-condensable gases
from the top of degassing column (C-02) are rectified in Heads column (C-03), to
expel the high volatiles, technically known as heads. Bottom liquid from the
degasser flows into analyzer column (C-01) where alcohol is stripped from the
liquid. The liquid from bottom of analyzer column (C-01) is completely stripped of
alcohol and is pumped out by thick slop discharge pump P-02 through heat
exchanger E-01 where it preheats the fermented wash before it enters degassing
column. The slop from the analyser column will be feed in to decanter. The dilute
alcohol vapors from near the top of analyzer column (C-01) are condensed first in
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beer heater (E-02) while exchanging heat with wash feed and then in analyzer
condenser (E-03). Degasser and analyzer operate under vacuum. The condensate
from E-02 and E-03 is collected in Rectifier Feed Tank V-02. The vapors for
stripping alcohol are generated from analyzer column bottom liquid in the analyzer
column re-boiler (E-04) by using the rectified column top vapors, as discussed
subsequently. Vapors from the top of heads column (C-03) are condensed in heads
column condenser (E-06) and then in head column vent condenser (E-07). Part of
the condensate is returned to column C-03 as reflux while a small portion is taken
out as an impure spirit cut. Liquid from bottom of C-03 is also taken into Rectified
feed tank V-02.Dilute alcohol water mixture from rectifier feed tank (V-02) are
pumped by rectifier feed pump (P-04) through rectifier feed pre-heater E-11 in
to rectifying column (C-04). Rectifier and its associated equipment work under
pressure so that these vapors can supply the necessary heat for generating the
vapors.
The condensate from E-04 is then pumped as Reflux to rectifying column C-04.
Rich alcohol vapors at a concentration of 95.5% v/v from top of rectifying column
(C-04) are condensed first in Analyzer (E-04) and then in Reflux Vent Condenser
(E-05). The liquid from E04 and E-05 are collected in Rectifier Reflux Tank (V-
01). Part of the liquid from E-05 may be drawn off as impure spirit. The impure
spirit cut will be maintained as little as possible to maintain aldehyde levels to meet
the required limits in Absolute Alcohol. Liquid from the reflux tank (V-01) is
pumped by Product Pump (P-03) partly as product and partly as reflux to the top of
the Rectifying Column (C-04). The necessary rectifying vapors to C-04 are
generated by boiling the C-04 bottom liquid in Rectifier Column Re- boiler E-08
using medium pressure steam. Some side streams are drawn from rectifier column
as light and heavy fractions of higher alcohols called fusel oils and cooled in fusel
oil coolers E-09 and E-10 and are mixed with water and allowed to separate out in
fuel oil separator F-01. All vents from E-03, E-07, V-02 and E-05 are connected to
Vent Gas Absorber (C-05) where the vent gases are scrubbed with water to recover
entrained alcohol. The scrubber water is used for washing the fuel oils in fuel oil
separator to recover alcohol from the fuel oil fractions. The absorber vent is
connected to vacuum pump (G-01) which is used to create vacuum in the analyzer
and degasser. Absolute alcohol is manufactured by dehydration of Rectified
Spirit. The process adopted here is based on Pressure Swing Adsorption (PSA)
system using Molecular Sieves (3-A). The flow scheme is shown in above referred
flow diagram. Rectified spirit, after preheating by waste hot streams, is vaporized
and superheated in E-03 and E-04 by using medium pressure steam at 6 Kg/cm2g
pressure. Hot vapors at kg/cm² g pressure and 130° C temperature pass through
PSA column S-01A/S-01B where the water vapors are retained while water free
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alcohol is released as vapors. The vapors are condensed in E-07 and E-08 and
collected as Absolute Alcohol. When the molecular sieve bed is saturated with
water the alcohol vapors are shifted to the other tower and the first tower is taken
for regeneration. Regeneration is done first by pressure releasing and creating
vacuum and then by elutriating with dehydrated alcohol vapors from the tower in
dehydration operation. The vapors are condensed in E-06 and E-05 and the vent
vapors are recovered through scrubber C-02. Vacuum can be created vacuum by P-
04. (Eductor may also be considered for this duty). Product is cooled in E-09 and
transferred to Absolute Alcohol receiving tank and then on to storage tank. This
process utilizes the following columns namely Analyser, Degassifier, Aldehyde,
Pre-Rectifier Column, P/R Stripper Column, Rectifier-cum Exhaust, Extractive
Distillation (ED) Column, Fusel Oil Concentration Column and Simmering
Columns. The Analyser, Degassifier, Aldehyde, Pre-Rectifier Columns are
operated under Vacuum whereas Simmering, Extractive Distillation, FOC Columns
are operated under Atmospheric condition. The Rectifier-cum-Exhaust Columns are
operated under Pressure.The energy requirement for Analyser Column & Pre-
rectifier is met by Rectifier Column top vapours. The Rectifier Column top vapours
are condensed in a thermo-siphon reboilers connected to a flash tank and then flash
vapours out of soft water feed are injected into Analyser Column.
The energy requirement of the Simmering Column is met by the top vapours of
Extractive Distillation Column while that of the FOC Column is through direct
steam. In the distillation scheme offered, all Columns are designed for all the
products.
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The system operates under vacuum. Water-ring vacuum pumps are used
to maintain a desired vacuum.
Cooling water from cooling tower is used in the surface condensers for
condensing the vapours.
CONCLUSION
The thick syrup thus obtained is mixed with the Wet Cake obtained from Decanter
Centrifuges using specially designed Ribbon type mixer and this enriches the
protein content in the fibrous suspended solids separated earlier in Decanter. This
Protein & Fiber rich DWGS is directly sellable as Cattle/ Poultry Feed. However,
in order to increase the shelf life of such by-product, it is necessary to dry the
product,with minimum possible moisture content.
During the course of rotation, these flights pick up the material and shower them on
to the tube bundles. The heat transfer is primarily by conduction. The water
vapours are exhausted through an Exhaust Blower & passed through a cyclone
separator for separating fines.Dry product partially recycled back to Feed
conditioner for feed conditioning through Product Screw & Recycle Conveyor.
Entire operation of the Dryer is controlled through Control panel.
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Following are the list of definitions used in this document, unless the context
otherwise requires: -
b) “chief incident controller” means the person who assumes absolute control of
the unit and determines action necessary to control the emergency;
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m) "occupier” of an installation means the person who has ultimate control over
the affairs of the installation;
o) “off-site emergency plan” means a response plan to control and mitigate the
effects of catastrophic incidents in above ground installation (AGI) or
underground installations (UGI) or road transportation. This plan shall be prepared
by the district administration based on the data provided by the installation(s), to
make the most effective use of combined resources, i.e. internal as well as external
to minimize loss of life, property, environment and to restore facilities at the
earliest;
q) “on-site emergency plan” means a response plan to contain and minimize the
effects due to emergencies within the installations which have a potential to cause
damage to people and facilities within the installation premises;
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s) “risk analysis” means the identification of undesired events that lead to the
materialization of a hazard, the analysis of the mechanisms by which these
undesired events could occur and, usually, the estimation of the extent, magnitude,
and likelihood of any harmful effects;
u) “risk management” means the programme that embraces all administrative and
operational programs that are designed to reduce the risk of emergencies involving
acutely hazardous materials. Such programs include, but are not limited to,
ensuring the design safety of new and existing equipment, standard operating
procedures, preventive maintenance, operator training, incident investigation
procedures, risk assessment for unit operations, emergency planning, and internal
and external procedures to ensure that these programs are being executed as
planned;
v) “site incident controller” means the person who goes to the scene of the
emergency and supervises the actions necessary to overcome the emergency at the
site of the incident;
x) “transport emergency (TREM) card” means a card containing details about the
nature of hazards, protective devices, telephone numbers and actions related to
spillage, fire, first aid and other details of national and international (UN) numbers
or signage which is common in India and abroad;
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Warning Phase
Many disasters are preceded by warning signals like liquid hydrocarbons leaks
developing into vapor cloud, weather forecast giving advance warning of
meteorological disasters, uncontrolled chemical reactions ending up in explosion
etc. Warning phase provides a cushion to put into action the remedial measures to
counter the disaster.
Period of Impact
This is the period when the disaster strikes and very little can be done to minimize
its impact. This period can last for a few seconds (as in case of explosions) to many
days (as in case of tank fire, natural calamities etc.)
Rescue Phase
The rescue phase starts immediately after the impact and continues until necessary
measures are taken to rush help to combat the situation and to evacuate people to
safer places.
Relief Phase
During this phase relief measures are organized internally. External help can also be
summoned to augment the internal resources.
Rehabilitation Phase
This is the final phase in disaster management, during this period, estimating the
damages, payments of compensation, rebuilding the damaged property etc. are
done. Inter disciplinary effort, total co-ordination within the organization is required
to be implemented and aid from statutory bodies, experts can be availed.
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SCOPE
INTENT
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OBJECTIVE
Objective of the plan are to provided a system, capable of taking fast and effective
action in a emergency situation in order to :-
i. Safe guard the factory personnel inside & public outside the factory.
ii. Effect the rescue & treatment of causalities.
iii. Safe guard the property and environment.
iv. Bring the incident under control.
v. Treatment of casualties, Head count, and information and assisting relatives.
vi. Provide authorities information to the news media.
vii. Ensure rapid return to normal operation after emergency.
viii. Preserve relevant records and equipment‟s the subsequent inquiry.
ix. Developing factory personal to ensure its at no panic on such occasion of
safe, skilled, action will minimize the casualities, injuries and damages of
other nature.
x. To maintain & culminate good image in public & National interst.
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The views of the possible hazards that can arise out of the daily operations in the
distillery plant, various measures are adopted to prevent the occurrence of a major
accident. This comprises of:
Built in safety measures, alarms, trips and interlocks etc.
Standard safe operating and maintenance procedures permit system etc.
Training of all the involved staff in normal and emergency operating
procedures.
Training of all employees in safety, fire fighting and first aid.
However, in spite of these precautions, it is required to foresee situation of major
accident and plan for taking timely action to minimize the effects of such incident
on the safety and health of persons working in the plant as well as those living
around the premises. Generally, Emergencies can be categorized into three broad
levels on the basis of seriousness and response requirements, namely: –
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Level-I and Level-II shall normally be grouped as onsite emergency and Level-III
as off-site emergency according to the hazards/risks associated as follow:
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group of people.
Natural Perils – Earthquake, Flood,
Tsunami Sabotage, Bomb Explosion /
Threat.
Exposure to pollutants released from
offsite/ storage/related activities
Contamination due to accidental
releases or normal release in
combination with natural hazard
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The common causes for the above events are tabulated below for reference and the
ONSITE EMERGENCY PLAN (OEP) should be prepared by the installation to
deal with the following emergencies.
Physical Properties:
Chemical Formula : C2H5OH Molecular Weight : 456.
Highly volatile, colourless, bitter in taste, surest smell, and highly inflammable
liquid. It is mixable in all proportions with water, eathers and other alcohol. Its flash
point is as low as 400 C and can catch fire at elevated temperature. It forms
explosive mixture with air, if mixed to the extent of 2.6% by weight. It has no
severe effect on skin or tissues if inhaled. It has fire hazard. Possible measures have
to be taken for arresting the same in time. Step has been taken to install sprinkler
system on and around the storage tanks.
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The alcohol will be directly fed to the bottling unit mechanically and no manual
handling will be involved which will reduce the risk of spillage in the storage area.
Following precautionary measures would be taken for safety:
Foam System for firefighting will be provided to control fire from the alcohol
storage tank. The foam thus produced will suppress fire by separating the fuel from
the air (oxygen), and hence avoiding the fire & explosion to occur in the tank. Foam
would blanket the fuel surface smothering the fire. The fuel will also be cooled by
the water content of the foam. The foam blanket suppresses the release of
flammable vapors that can mix with the air.
Special Fire Fighting Procedures; Keeping the fire upwind. Shutting down of all
possible sources of ignition, keeping of run-off water out of sewers and water
sources. Avoidance of water in straight hose stream which will scatter and spread
fire. Use of spray or fog nozzles will be promoted, cool containers will be exposed
to flames with water from the side until well after the fire is out.
Hazardous Decomposition Products: gases of Carbon Monoxide (CO) & Carbon
Dioxide (CO2).
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ELECTRICAL HAZARDS:
Though, flame, proof fittings are provided Electrical injuries may occur any where.
It may be caused by direct current, alternative current or from lightening. The
security of the injuries by electric shock depends upon :
1. The amount of current flowing through the body.
2. The path of current has taken through body to the earth. A weaker current
passing through the chest is more dangerous than a relatively stronger current
passing through the lower limits.
3. Length of the victim is in contact.
4. Type of electric energy AC or DC.
5. Physical condition of victim.
Any delay in first aid in electric shock is a delay for ever, hence the person Giving
the first aid must not get excited and must not endanger his life.
1. The current must be cut off or the plug should be pulled out.
2. He must not touch the victim or the live conductor.
3. If it is difficult to cut the current, the victim has to be separated by using a
dry coat rope, stick etc.
4. If there is the dry wooden chair or rubber sheet, he must stand on it and then
separate the victim.
5. If the cloths are smoldering, the spark should be extinguished.
6. Artificial respiration is to be started immediately. This may be done
whenever the victim is in unconsciousness while the pulses. The artificial
respiration should be continued till the doctor has arrived one may like to continue
for atleast 8 hours before obarconing the case as dead.
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When the patient start swallowing, one may understand that spontaneous breathing
is being received. Artificial respiration should be continued till normal movement
of breathing is fully established as the respiration may falls again if left earlier.
7. A blanket should be out around the patient. The patient has be kept warm to
treat the shock. He may be given warm, sourest drink if he is conscious otherwise
not, as it may harm him.
8. Superficial bones of lightening strange may be covered with a septic
dressing. The deeper bums caused from contact with live conductors may be
covered with clean sheet and the patient taken to a hospital without any further
delay.
9. External cardiac massage may be given if the pulse is not felt or even
artificial respiration.
Power Cables
It is to be secured properly. It is to be protected from physical hazards. All junction
boxes should be protected and supported. Checking of ear things is necessary. All
junction box should be filled with compound.
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c. Manpower data
All the staff at the installation is trained in firefighting and all new staff is given
charge after undergoing extensive firefighting training. In addition, trained staffs
are given refresher training courses periodically.
The details (designation) and duties of the staff are given below in the “Fire
Organization Chart”.
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e. Organization chart.
Affected Stake
Holders and Off-Site Incident
Government Commander
Authorities (District Medical Services
Magistrate) and Ambulance
Municipal transport
rescue and
rehabilitation team
Fire Brigade
Services
Police
Services
CHIEF INCIDENT
CONTROLLER
Mutual Aid
SITE INCIDENT
CONTROLLER
Level – I
Level II
Level III ---------
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Note:*
(1) Above is a typical and basic organogram for control of emergency. Entity can
merge the functions as per their other statutory requirements and based on
level of risk and range of operations. The organization shall have to address
all services and support system required and available to it.
(3) Role of both CIC and SIC can be merged depending upon the requirement.
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Additional Teams
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Start using water from nearby hydrant/ monitor/ foam as the case may be till fire
is extinguished as per wind direction.
Receive instructions from fire chief & coordinate for operation of firefighting
equipment‟s.
In case of other emergency like leakage of product, arrest the source while it is
being diluted with fine water spray.
Keep on updating information to fire chief & suggest for necessary assistance if
required.
After getting clearance from fire chief & hearing clear siren, assemble at
assembly point.
2. Auxiliary team
Rush to the site & report to fire chief.
Coordinate with fire combat & rescue team in charges for replenishment.
Collect fire extinguishers, nozzles, foam nozzles, foam cans & make them ready
to supply all these to fire combat team members at the spot of fire.
Keep on updating information to fire chief.
3. Rescue team
Reach at the site & report to fire chief.
To coordinate for PPES/ evacuation/ first aid/stretcher/ rescue operations.
To identify casualty & give first aid.
Keep on updating information to fire chief.
Give head count to fire chief.
To safe guard documents, records & other important files.
To communicate with mutual aid members, district administration, police, fire
brigade & other external agencies & controlling office.
Arrange drinking water & food.
Communicate with public arriving at gate.
Security Coordinator
The Security Coordinator reports to the Chief / Site Incident Controller and is
responsible for security of the installation during any incident or emergency
situation and for implementing the actions below:
a) Obtaining an approved visitor list from the security department or reception for
ensuring that personnel on the list are escorted to reception by security staff;
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Note- Plans shall also be developed to utilize local media and television stations for
periodic announcements during an emergency. This shall also assist in reducing
rumors and speculation.
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Recorder
The Recorder responsibility is to maintain an accurate time record of key
information received from the incident or emergency location and to record the
actions initiated by the site incident controller and for implementing the emergency
response actions below:
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i. Classification of Fire
A small spark of fire may result into loss of machines and the damage by fire may
high economic losses. This type of losses can be avoided by preventing and
controlling the fire instantly for which fire–fighting group will be established.
Different classes of fire are explained as follow:
Class (A)-Fire involving combustible materials like wood, paper, cloth etc.
Class (B) -Fire due to liquid materials like oil, diesel, petroleum products and all
inflammables.
Class (C) -Fires involving domestic and industrial gases like butane and propane
etc.
Class (D) -Metal fires etc.
Class (E) -Electrical fires due to short circuiting etc.
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Establish which would house and keep in readiness, the following types of
equipment and arrangements. CO2 extinguishers, Dry powder chemical
extinguisher, Foam extinguishers ,80 mm. spray hoses ,Fire brigade,Fire hydrant,
Protocol (chemical to combat oil fires). In order to avoid fire in cable galleries, all
the power and control cables of FRLS type (Fire Resistant Low Smoke) will be
used.
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d) Ensure stand, painted fire red with rain protection cover for extinguishers
placed in open
e) Ensure that no extinguisher is placed on the ground
f) Ensure max. running distance to locate extinguisher does not exceed 15m
g) Ensure that top surface of installed extinguisher is not more than 15 m above
the floor/ground level
h) Ensure minimum 10% of the total refills in the extinguisher is maintained at
the location
i) Ensure that extinguishers are painted whatever required and bottom of the
extinguisher are always in good condition
j) Ensure that any extinguisher failing in hydro test is condemned
k) Ensure that hydro testing of fire extinguisher is carried out once in five year
vi. SOP for Fire Detection & communication System
In case of emergency, nearest MPC to be operated, this will indicate an alarm in the
fire alarm panel present in the control room and repeat panel in the security cabin
Ensure that:
a) Security has access to direct telephone after office hours
b) Availability of emergency telephone numbers list in security cabin and other
important places
c) That the handle of hand operated sirens are attached to the sirens.
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The available emergency control systems and facilities within the installation shall
be as under: -
a) fire and gas detection system
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Sr.
No. Check-point
1 Whether mock fire / emergency response drills are held
2 If yes, periodicity of emergency response drills
3 Mock drills cover all types of probable emergencies
4 If yes, the details of other members including names and contact nos. of
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concerned officials
5 List of fire fighting equipments available
6 Compatibility of safety equipment including District Fire Services with
said location has been tested and documented in the DMP
7 Details of water storage available including District Fire Service and
mechanism to utilize the same in the said location well documented in the
DMP
8 Details of firefighting foams concentrate/chemicals available including
nearest Fire Service has been incorporated
9 Details of lead time for response of District Fire Service has been
documented in the DMP
10 Periodicity of safety training for officers, staff, contractor workers, TT
crew and security personnel mentioned in the ONSITE EMERGENCY
PLAN (OEP).
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Employee/
Police Security
Public
Fire and gas
detection
system/ SCADA
EMERGENCY
System
CONTROL
CENTRE
(ECC)
First MANAGEMENT
Responder TEAM
(Head Operations, Head CRISIS
Maintenance, Head MGMT
Technical, Head HSE, GROUP
SITE INCIDENT
Fire safety/HSE Head Security, Head
Coordinator and CONTROLLER
(HR)
fire team
District
CHIEF INCIDENT Administration
and Central
CONTROLLER
Govt. agencies
Info. to Fire Mutual Aid
Brigade, Police, Members
Medical and
Government Others (required Note: Level I
Authorities coordinators of the
installation) Level II
Level III
Note:
1. above is a typical communication flow chart for notification of emergency.
2. Wherever communication exists for any level of emergency, it automatically
implies that the communication exists for all higher levels of emergencies.
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and actions, or carry out protective measures; this can be achieved only if the
people are familiar with the alarm systems and are trained to respond to it.
To direct and coordinate the operations, the administrative/office building has been
nominated and developed as the Emergency Control Center. In an emergency it is
almost essential to evacuate affected person from inside the factory to a safer place. It
is also essential to evacuate non-essential workers to streamline Emergency Action
Plan activities and ensuring safety of those people. The evacuation will be effected
after getting information from the Works Incident Controller soon after emergency
arises. On evacuation all contract laborers, visitors etc. other than those notified as
team member shall assemble at the assembly point for receiving further instructions.
At the time of the emergency On-site Chief Controller assisted by other designated
coordinators shall take position here to perform their duties. Its location is outside the
area of potential hazards and is easily approachable.
Both the Emergency Control Center have the following resources available at all
times:
4 Copies of the On-site Emergency Plan.
Layout Plan of the complex.
Plans of work illustrating the following:
Plan of chemical storage tanks with pipeline details
Sources of safety equipment
Fire Hydrant System Layout
Stock of firefighting equipment
Location of assembly points
Location of works in relation to surrounding community
A list of telephones of key and essential staff of the company along with their
addresses and residential numbers.
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Escape Routes -The roads leading to the Assembly Points are the designated
escape routes. The escape routes will be clearly marked with arrow marks for easy
escape.
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The assembly point should be clearly marked with directional display board along
the route. Route should be well lighted with florescent marking.
During an emergency, pre-designated persons would take charge of this point and
take the roll call of the people reporting. Provisions should be made for assembly
points, communication and headcount facilities at assembly points, and personnel to
control the movement of assembled employees.
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specialized treatment units for a wide variety of ailments and medical conditions. It
has therefore not been required by any organization to build up its strong in-house
facilities.
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Potassium Permanganate
Iodine Tincture
Cotton
Scissors
Savlon
viii. Evacuation
1) Planning and training on evacuation techniques are important in preventing
injuries. Evacuation of local communities or people near the site may be prudent
depending on the situation and down-wind dispersion information etc. Although
this action will normally be initiated and handled by district authorities, the
affected installation shall help to implement such evacuation.
3) If evacuation takes place after initial head counts are reported, means for
recounting may be necessary. Where it is safe to do so, areas being evacuated
should be thoroughly searched to ensure everyone has departed safely. Portable
mobile vehicle for announcement should be available in the emergency.
For the purpose, use of Dos' and Don‟ts' shall be prepared and furnished to the Crisis
Management Group. Display boards carrying do‟s and don‟ts should be located
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outside the gate as well as in the neighboring colonies and other habitat areas in the
immediate vicinity.
The termination of emergency shall be declared through siren as per the Siren Code
defined by industry in case of Level- I and II. For Level-III termination of emergency
shall be declared by District Authority through appropriate mode of information
transfer so as to reach each and every one.
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The Central Government is empowered to take further measures as it deems fit for
the purpose of disaster management like deployment of naval, military and air forces,
other armed forces of the Union or any other civilian personnel as may be required
for the purposes of this NDMPAct. Government of India is empowered to establish
institutions for research, training, and developmental programs in the field of disaster
management as per this Act.
The national vision is to build a safer and disaster resilient India by developing a
holistic, proactive, multi-disaster and technology driven strategy for NDMP. This
will be achieved through a culture of prevention, mitigation and preparedness to
reduce the impact of disasters on people. The entire process will centre stage the
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community and will be provided momentum and sustenance through the collective
efforts of all government agencies supported by Non-Governmental Organizations
(NGOs).
Note: Since PNGRB has been constituted by PNGRB Act, 2006, it should be
identified under Ministries / Departments of Govt. of India.
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xviii. Glossary
DMP Disaster Management Plan NH No hazard from the event
Impact criteria level Not
OEP Onsite Emergency Plan NR
Reached
HAZCHEM Hazardous Chemical IRPA Individual Risk per Annum
Unconfined Vapour Cloud
CFO Chief Fire Officer UVCE
Explosion
HSE Health Safety Environment MSDS Material Safety Data Sheet
TT Tank Truck QRA Quantitative Risk Assessment
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Sr.
No. Check-point
1 Which of the following procedures or techniques for hazard identification has
been used in the IRD/ installation :
1) HAZOP/HAZAN
2) Incident Consequences and Analysis
3) Event Tree Analysis
4) Fault Tree Analysis
5) Failure Modes, Effects and Criticality Analysis
6) Risk Assessment
7) What if, analysis
8) Other accredited practice
Hazard Identification :
2 Is the installation covered under the definition of “Major Incident Hazard
Installation” as per the Manufacture Storage and Import of Hazardous
Chemicals Rules 1989 (Amended 1994 and 2004. If yes, please specify the
site notification and safety reports
3 If yes, whether major Incident hazards identified and steps taken for their
prevention
4 Whether design deficiencies, failures or errors which can contribute to hazards
and cause abnormalities leading to an Incident are identified
5 What are the measures undertaken to counter above deficiencies or, errors
6 Consequences of a major Incident on the workers, people in the
neighborhood and the environment are considered
7 Steps envisaged for mitigation of the consequences of such incident
8 Does the installation produce / handle / use / import / store any hazardous
chemicals as defined under MSIHC Rules 1989 (Amended 1994 and 2004)
9 If yes, whether a list of these chemicals, preferably in alphabetical order with
their maximum licensed storage quantities is displayed
10 Are material safety data sheets (MSDS) of these chemicals are prepared /
obtained in the prescribed format as per MSIHC Rules and State Factory
Rules
11 Whether a system for disseminating information about these MSDS to
concerned workers are existing
12 Are there a system of labeling of containers / storage tanks for the chemicals /
hazardous substances
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Sr.
No. Check-point
1 Whether Safety, Health and Environment Policy of the location is displayed
2 Whether the Safety Policy is documented and duly approved by the top management
3 Whether the Safety Policy is well structured to cover all elements of Safety, Health and
Environment protection
4 Whether the layout is convenient from operation and safety aspects and meets
minimum distance norms
5 Whether a duly constituted Safety Committee is functioning in the location with
representation from workmen/staff
8 Whether all unsafe developments and likely risks are deliberated in the meetings and
appropriate steps are recommended for eliminating such risks
9 Whether compliance status of recommendations of earlier Safety Committee meetings
are discussed before taking up new issues.
10 Whether performance and shortcomings observed during recent mock disaster drills
form part of the discussions in safety committee meetings
11 Is the safety committee minutes are recorded and signed by all the attending members
13 Whether periodical safety audits and inspections by internal and external audit teams
are conducted in defined intervals
14 Whether a system of regular monitoring of such audit compliances by controlling
offices / HO are in place
15 What is the composition of external audit teams to ensure impartiality of audit findings
16 Whether Work Permit System have been implemented
17 Whether work permits are issued for hot work, cold work, electrical work and vessel
entry jobs
18 Whether the location-in-charge or his authorized nominee remain the issuer for all hot
work and vessel entry permits for enhanced safety and control.
19 Whether work permits are duly closed at completion of the stipulated jobs, duly
certified by the supervising officer
20 Whether heat detectors in tank sprinkler systems, high level alarms of tank farm
management system are provided and checked for regular functioning
21 Whether in-built safety interlocks provided in the design are adequately specified and
checked for regular functioning
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CHEMICAL DATA
SL NAME OF THE COMMERCIAL STORAGE METHOD BELOW/ ABOVE
NO CHEMICAL TECHANICAL QUANTITY OF THE GROUND
NAME STORAGE
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