ON SITE EMERGENCY PLAN OF
M/S VIVIMED LABS LIMITED Survey No.207/AA,207/A,207/E Bonthapally (V), Jinnaram (Mdl) Medak (Dist) – 502313.A 5023 13.A.P .P..
JANUARY - 2008 .
EMERGENCY PLAN
1.1 INTRODUCTION:
Emergency planning is an integral and essential part of loss prevention strategy. The type of emergency primarily considered here is the major e mergency which may be defined as one which has the potential to cause serious danger to persons and or damage to property and which tends to cause disruption inside and or outside the site and may require the use of outside resources. Emergency is a general term implying i mplying hazardous both inside and outside the installations. Thus, emergencies are termed “On-Site” when it confines itself within the plant even though it ma y require external help and “Off-Site” when emergency extends beyond its premises. It is to be understood here, that if an emergency occurs inside the plant and could not be controlled, it may lead to an off-site emergency e mergency..
1.2 OBJECTIVES OF THE PLAN:
Emergency Planning or preparedness is a comprehensive response plan to react to a number nu mber of foreseeable emergencies anticipated in the works and to contain the loss of human life, Property and provide speedy and effective remedial measures. I mportant prerequisite for emergency planning is to foresee an accident scenario which leads to a major fire, explosion, toxic release, their spread or extent and their damage potential. These information are used in conjunction with layout of the units in the works, and adjacent communities in the preparation of the contingenc y plan. Identification of scenarios and their consequences from important element in the emergency planning. The type of scenarios and their consequences determine the emergency response. Identification of scenarios and mitigation include the detection of abnormal conditions, c onditions, assessing the potential consequences and immediate measures to mitigate the situations. This include emergency response action which must be taken to protect the health and the safety of the plant personnel and the public. Assuming all reasonable plant safety design and their improvements have been considered like design codes, practices alarms, shutdown interlocks etc., the accidents may occur as the plant operating parameter valves may exceed or lie out side the normal parameters. These potential uncontrollable parameters give the plant operators an indication of consequences in advance of actual occurrence. The important elements of emergency planning can be broadly classified as follows. i.
Iden Identi tify fyin ing g the the disa disast ster er pote potent ntia iall sce scena nari rios os and and adv advan ance ce plan planni ning ng to comba combatt and and minimise the damage.
ii. ii.
Disas Disaste terr phas phasee i.e. i.e. war warni ning ng,, prot protec ectiv tivee actio action n like like eva evacu cuat atio ion n of pers person onne nell etc. etc.
iii. iii.
Cont Contai ainm nmen entt of of dis disas aste terr by by isol isolat atin ing, g, fire fire figh fightin ting g etc etc..
iv. iv.
Rescue Rescue,, reli relief ef assist assistanc ancee to the people people affect affected ed in the works works / comm communi unity ty effec effectiv tively ely and efficiently based on the actual needs and on the information collected locally both in advance of the disaster and as soon as possible after the disaster occurred.
v.
Final Finally ly whe when n the the situ situati ation on is is cont contai aine ned, d, eff effor orts ts are are to to be retu return rn bac back k to nea nearr norm normal al conditions.
Of the above points, the first four are most relevant to the immediate attention t o works management. The areas affected by each accident scenario can be identified by their consequences like Pool Fire, Flash Fire and Toxic gas release. It would be appropriate to classify the hazards around the plant and to provide emergency measures in the area both onsite or offsite (if the zone extends). 1.3 ALERT:
It is the duty of any witness of the beginning of an accident or of an anomaly which might lead to an accident to give the alert and to act with available means within the limits li mits of his ability. ability. Alert is the information given to ask for assistance, in principle using alarms which are inside or outside the establishment. M/S.VIVIMED LABS LIMITED., has to ensure through training / information that any person of the staff give brief and precise warning message indicating the place, type and seriousness of the accident, whenever he is witness to an abnormal initiating event. Depending on the nature and magnitude of the event and local condition such as meteorology meteorolog y, geographical layout, la yout, population distribution and accessibility, accessibility, the important i mportant aspect to be considered is the type or level of an emergency. emergency. Emergency may be broadly categorized into four levels depending upon the implant facilities and extent of external help required to meet the emergency. emergency. The level 1 emergency is combated at the plant’s level and no external help in the form of facilities of expertise is required. In other levels, external help is required to combat the emergency as indicated below:
Level 1 :
Operation / Unit level
Level 2 :
Local / District level
Level 3 :
State / National level
Level 4 :
International level
1.4 ORGANISATION:
Emergencies very rarely occur as such they are not a day to day activity or a planned activit y which a fixed time schedule. The activities during the emergencies are to be coordinated and this could be achieved by an organizational approach, which has quid response capabilities.
This organization is capable of quick response any time of the day or night to meet the disasters. The emergency response coordination is critical to the protection of properties and lives of the workers and community. 1.5 CHAIN OF COMMAND:
Organisational structure should lay stress on the execution and speedy implementation of the response plans. At the same time it should be flexible enough to tune itself to the fast changing situations in the affected area. All actions are to be coordinated well so that overall situation is under control. The duties and responsibilities of each individual coordinator are fixed such that the action are taken with logical approach. If any changes are to be made in the procedure, or in actions, the front end area coordinator should be able to respond in logical fashion. To To achieve the above a chain of command is created with tiered structure that the supervisors can take a few independent decisions to achieve the overall objectives. The chain of command naturally naturall y corresponds to the organizational structure with clear understanding of the nature of duties and objectives. Every coordinator responsible for his area ensures that right type of trained people are deployed for the jobs to be done. Here, it ma y be pointed out that conducting mock emergency drills on a regular basis help the coordinators to understand the duties and responsibilities well. With feed back and experience gained from these drills, the command structure can be improved. The coordinator does not leave the command post unattended. If the coordicator is required to leave the command post for any reason, he has to deploy an alternate to attend the functions.
EMERGENCY FACILITIES
2.0 EMERGENCY FACILITIES:
Communication System Wind Sock Emergency Transport Vehicle First Aid, Fire fighting Equipment located in different areas in the block and utilities areas. Eye wash fountains Personnel Protective Equipment
Self contained breathing apparatus. 2.1 EMERGENCY CONTROL CENTRE (ECC):
It is a location, where all key personnel like Site Controller, Incident Controller etc., can assemble in the event of on site of emergency e mergency and carry on various duties assigned to the m. All necessary facilities are to be available. For the present the Time Office is identified as the Emergency Control Center. It is accessible from plant side. Emergency coordinator is responsible for maintenance of ECC and security officer assists him in this. 2.2 FACILITIES AT AT EMERGENCY CONTROL CONTR OL CENTRE (ECC):
Emergency Control Center plays a vital role to control emergency of any an y magnitude. Following material is normally kept available in Emergency Control Center: 1. Telephone elephone set for for quick quick communicat communication ion with teleph telephone one directory directory.. 2. Battery Battery operated operated public public address address system system (mega-phone (mega-phone)) to warn populat population ion in the vicinity vicinity about imminent danger, if any. 3. Drawing Drawing showing showing variou variouss locations locations around around the mills mills within within 5 Km radius. radius. 4. Proc Proces esss flow flow cha chart rts. s. 5. Fact Facto ory Lay Layout. ut.
6. 7. 8. 9. 10. 11. 11. 12. 13. 14.
Torch orch and and Emer Emerge gency ncy Lam Lamps ps.. Wirin iring g mate materi rial al Medi Medici cine ness for for fir first st-a -aid id Self-C Self-Cont ontain ained ed breat breathin hing g appara apparatus tus sets sets Spare Cylinder Cylinder for for SCBA. SCBA. Canister Canister type type gas gas mask mask Safety Safety Helmets Helmets Portable Portable chlori chlorine ne monitor monitor Copy of the on-site on-site emergency emergency management management plan. plan.
Address with telephone numbers and ke y personnel, and essential employees, Government agencies, neighboring industries and sources of help, outside experts, che mical fact sheets.
2.3 ASSEMBLY POINTS:
Assembly points are those locations where the persons who are not connected with emergency operations can await either for further instructions or for rescue transport and rehabilitation. Presently Time office is considered as such assembly points. For an y reason this assembly points becomes vulnerable for consequences of fire, the persons can go out of the factory gate and assemble outside. Assembly points are manned by Time Office persons and they work under the control of Emergency Coordinator. Coordinator. 2.4 EMERGENCY PROCEDURES:
Whoever notices an emergency identified above or a grave situation which has potential to develop into an emergency should forthwith raise an alarm by shouting or approach his plant shift in charge and informs him the details. 2.5 EMERGENCY COMMUNICATION:
Whoever notices an emergency of fire or gas leak, shout as “Fire, Fire, Fire or gas leak, gas leak, gas leak” in the regional language, as the case may be. He would rush to the shift in charge. 2.6 WHEN EMERGENCY IS COMMUNICATED BY TELEPHONE PARTICULARS TO BE INFORMED:
Identify each other, Inform incident / location / any precise further information he can give about accident. Shift in charger rushes to the scene, assess the situation and inform the Incident Controller / Site Controller / Security. While doing so, he would initiate measures to protect himself and to controlling the emergency. emergency. 2.7 EMERGENCY EM ERGENCY WARNING: WARNING:
At present there is no arrangement of siren in the plan. One emergency siren would be procured and installed so that it is audible to the entire plant area. Its operating plant would be located in ECC. Security on the authorization of Site Controller would operate. As there is no arrangement for normal siren, any siren operation means that there is an emergency in the plant. 2.8 ALL CLEAR:
Site Controller in consultation with Incident Controller and after ensuring that the emergency situation is overcome would order for all clear signal indicating that emergency is over come. All clear signal is organised by Security Officer continuous siren for 3 minutes is the All Clear Siren. These sirens would be made familiar to all employees. It would be ensured that in the surrounding industry, industry, there is no similarity in normal or emergency sirens of this plant.
2.9 EMERGENCY ACTIONS:
Who ever notice an emergency will bring it to knowledge of Site Controller and he verifies about it as quickly as possible. Once the emergency is confirmed, Site Controller would declare on set of On Site E mergency and Order security to raise emergency alarm through out the plant. Incident Controllers and shift in charge organise to co mmunicate emergency orally and by hand bells by shift in charges. At the same time, ti me, these with emergency responsibilities, key personnel and essential employees are expected to undertake specified emergency duties. Once emergency is known, all key ke y personnel would rush to emergency control centre (ECC) and assist Site Controller in the Management. The incidents Controller remain in their respective Production Block and take necessary measures to minimize effects of emergency. The Incident Controller in whose block emergency has arisen, would initiate measures for controlling and other Incident Controllers take measure to minimize the effects in their respective Production Blocks. Such emergency measures include the following: Safe shutdown of plant and equipment Evacuation of vulnerable blocks Control of cause of emergency such as fire or gas leak Taking measures to avoid spreading of effects of emergency to other areas. Plant personnel should take emergency shut down of the plant operations and swiftly and carefully move to Assembly Point. Essential Employees, if they are on plant round or so move to their usual place of work and await instructions. If they are aware of nature of emergency, emergency, they take necessar y steps to control situation causing emergency, emergency, by taking precautions to protect themselves and to protect properly, properly, prevent spreading of emergency e mergency..
Diesel Generator Operator would be ready to start the emergency equipment if required and if generator is not in operation. In the event of fire accident, electrical operator would switch off power supply in that block enabling fire fighting operations. Water pump operator would change the system and make arrangements for water for fire fighting operations. 1. EMERGENCY LIGHTING: A set of flood lights would be installed, focusing each operating block, from outside. The lights would be on mains, directly connected from panel room so that when a particular section or whole plant is cut off with power supply, the flood lights can be on, enabling emergency movement and emergency operations. 2. EVACUA ACUATI TION ON::
In the event of evacuation is decided, persons gathered at assembly points, and those who are in the plant are evacuated by using the available transport and also the transport drawn through Mutual Aid arrangement. Every Operating floor has two stair cases minimum and these would be used as emergency escapes. Each staircase would be marked as Emergency Escape. Electrical Supervisor is responsible for proper lighting of these staircases i n night and any an y fused bulbs should be replaced. Production chemist is responsible for maintaining these escape staircases free from obstructions at any point of time. At assembly point security arranges evacuation if required to far off place out side the plant. All these operations are under the control of Emergency Coordinator. Coordinator. NON ESSENTIAL WORKERS AND OTHERS:
Persons from outside or other workers, contract, casual workers who are not connected with emergency operations must withdraw from the plant where emergency occurred, to either assembly point or other safe location and await instructions. Incident Controller arranges sending away of non essential employees to either assembly a ssembly point or to outside gate. Road Tankers, Tankers, Lorries drivers, cleaners with draw the vehicles beyond the factory to safe location and await at that place for an y emergency instructions like evacuation etc., Security organizes sending away of waiting trucks to a far off place. BEYOND NORMAL WORKING HOURS & HOLIDAYS:
Being a process industry the procedure is same at any time either beyond normal working ours or holidays etc. FAMILIARISATION:
OSEP would be familiarized to all the employees including those in security and frequently visiting persons to the factory factor y, Essential Employees and ke y personnel.
KEY PERSONNEL RESPONSIBILITES
3.0 KEY PERSONNEL RESPONSIBILITIES: CATEGORY – I EMERGENCY:
Such as Fire, Explosion, Minor Toxic Release Etc., Emergency Control Leader (ECL) Departmental Head / In-Charge EMERGENCY CONTROL TEAM MEMBERS (ECTMs):
1. 2. 3. 4. 5.
Shif Shiftt in cha charg rgee / Supe Superv rvis isor or Shif Shiftt Eng Enginee ineer r Shif Shiftt Oper Operat ato or Shi Shift Fitter ter Shif Shiftt Elec Electr tric icia ian n
DUTIES OF EMERGENCY CONTROL LEADER (ECL):
1. To direct the the shift in charge charge / Superviso Supervisorr to control control emergency emergency on receivin receiving g information information and to proceed to site quickly. 2. Assess Assess the the emer emergency gency – type type and categ category ory.. 3. Commun Communica icate te concer concerned ned person persons. s. 4. Take necessary necessary steps steps to organize organize the manpower manpower and resources resources for controll controlling ing the emergency emergency and direct ECTMs accordingly.
5. Advise Advise the personn personnel el form site site to move move away to safe safe place, place, if needed needed and send send for medical medical assistance in case of casualty. DUTIES OF ECTMs ON DUTY:
1. To direct the the shift in charge charge / Superviso Supervisorr to control control emergency emergency on receivin receiving g information information and to proceed to site quickly. 2. Assess Assess the the emer emergency gency – type type and categ category ory.. 3. Commun Communica icate te concer concerned ned person persons. s. 4. Take necessary necessary steps steps to organize organize the manpower manpower and resources resources for controll controlling ing the emergency emergency and direct ECTMs accordingly. DUTIES OF KEY PERSONNEL:
1. 2. 3. 4. 5. 6. 7.
Fir Fire Of Officer Saf Safety ety Off Officer icer Secu Securi rity ty Of Office ficer r Welfa elfare re Offi Office cer r Time ime Off Offic icee in in Cha Charg rgee In char charge ge / HOD HOD Fac Factory tory Man Manager ager
DUTIES OF FIRE OFFICER & FIRE FIGHTING CREW:
a. b. c. d.
Procee Proceed d to site site afte afterr receiv receiving ing the the mess message age.. Assist Assist ECL in emergen emergency cy cont control rol.. Assist Assist ECL in investig investigation ation and follow follow up of remedial remedial measur measures. es. Set right right and reinstate reinstate fire fightin fighting g appliances appliances in their their position position after after the emergency emergency is under under control.
DUTIES OF SAFETY OFFICER:
a. b. c. d.
Procee Proceed d to site site afte afterr receiv receiving ing the the mess message age Assist Assist ECL in emergen emergency cy cont control rol Arrange Arrange for for manpower manpower to deal deal with emergency emergency as as per requirement requirement Shifting Shifting to hospit hospital al as needed needed and and first first aid to affected affected persons. persons.
DUTIES OF SECURITY OFFICER:
a. Procee Proceed d to site site afte afterr receiv receiving ing the the mess message age.. b. Standby Standby for furthe furtherr info informat rmation ion c. Assist Assist ECL in emergen emergency cy contro controll DUTIES OF WELFARE OFFICER:
a. Procee Proceed d to site site afte afterr receiv receiving ing the the mess message age.. b. Assist Assist ECL in emergen emergency cy cont control rol c. Arrange Arrange for shifting shifting the affected affected person personss to hospital hospital and make make arrangements arrangements for for first aid as per requirement. DUTIES OF TIME OFFICE IN CHARGE:
a. b. c. d.
Procee Proceed d to site site afte afterr receiv receiving ing the the mess message age Assist Assist ECL in Emergen Emergency cy cont control rol Arrange Arrange for for manpower manpower to deal deal with emergency emergency as as per requirement requirement Shifting Shifting to hospit hospital al as needed needed and and first first aid to affected affected persons. persons.
DUTIES OF HOD / INCHARGES:
a. b. c. d. e.
Procee Proceed d to site site afte afterr receiv receiving ing the the mess message age Assess Assess the the situa situatio tion n and info inform rm presi presiden dentt Assist Assist ECTMs ECTMs in emerg emergency ency contro controll Co-ordinat Co-ordinatee the working working of variou variouss sections sections and guide ECTMs ECTMs for for plant shut shut down. down. Collect Collect all necessary necessary information information and and investiga investigate te the cause cause of the incide incident nt to take remedia remediall measures to prevent recurrence.
DUTIES OF O F FACTORY FACTORY MANAGER:
a. Procee Proceed d to site site afte afterr receiv receiving ing the the mess message age b. Initiat Initiatee action action to inform inform statu statutory tory auth authori oritie tiess c. Co-ordinat Co-ordinatee all security, security, medical assistanc assistance, e, personnel personnel evacuation evacuation activitie activitiess as required. required. DUTIES OF PRESIDENT:
a. Procee Proceed d to site site afte afterr receiv receiving ing the the mess message age b. Assess Assess the the situati situation on and and inform Executive Executive Director Director c. Guide the the ECL/ECTMs/Fa ECL/ECTMs/Factory ctory Manager Manager or or emergency emergency contro controll and coordina coordination tion of working working of various sections CATEGORY CATEGORY – II I I EMERGENCY: EME RGENCY: RESPONSIBILITIES DURING SECOND & THIRD SHIFT DUTY:
During shift operation, Production Chemist / in charge to take control of the emergency and immediately inform Main Incident Controller, Administration Administration & Communication Coordinator and Safety Coordinator. He shall discharge the duty of Main Incident Controller till the Main Incident Controller arrives and takes charge. Similarl y, two Asst.Chemists - Shift to change and
responsibility of Administration and Communication coordinator & Safety Coordinator till the y arrive and take change. 3.1 RESPONSIBILITIES OF COORDINATORS / CONTROLLERS: A. MAIN INCIDENT CONTROLLER:
For On-Site Emergency Plan, the location in charge i.e., General Manager shall be the Main Incident Controller to coordinate the execution of the plan during an emergency or a mock drill. He is responsible for preparation / updation of the plan, getting approval from the District Authorities / Factory Inspectorate; and its implementation in the hour of need. His duties are :a.
Assess Assess the magnitude magnitude of the situati situation on and declare declare state state of emergency emergency.. Activate Activate OSEP and ensure its implementation.
b. Mobilise Mobilise the Main Coordin Coordinators ators / Key person personnel nel and exercise exercise direct direct operation operational al control control of areas, other than those affected. c.
Declare Declare danger danger zones zones and and activate activate Emergency Emergency Control Control Center Center..
d. Ensure Ensure calling calling in Mutual Aid members members and district district emerge emergency ncy agencies agencies like like Fire Brigade, Brigade, Police, Medical authorities. e.
Maintain Maintain a speculativ speculativee continuous continuous review review of possible possible developm developments ents and and assess assess these to to determine more probable course of events a nd appropriate response.
f.
Inform Head Office, Office, Police, Police, Statutory Statutory authorities authorities,, District District Author Authorities ities about about the magnitu magnitude de of the emergency casualties and rescue operations.
g. Ensure Ensure casualties casualties are receivin receiving g required required attention attention and their their relatives relatives are informed informed.. h. Ensure Ensure accoun accountin ting g of of pers personn onnel. el. i.
Issue Issue authorized authorized statemen statements ts to Press, Press, Radio, Radio, TV etc., regard regarding ing the the emergency emergency and its possible impact on the surroundings.
j.
Author Authorise ise procur procureme ement nt of of emerg emergency ency mater material. ial.
k. Log important important developme development nt in chronolog chronological ical order order and preserve preserve material material evidence evidence for investigation. Direct isolation of power supply, supply, plant shutdown and evacuation of personnel inside the premises pre mises as deemed necessary. l.
Advice Advice Police, Police, District District authorit authorities ies regardin regarding g evacuation evacuation of of public public in the the near vicinity vicinity / vulnerable zone. Ensure raising the sire in EMERGENCY mode till All Clear Signal.
m. When effects effects are likely likely to be felt outside, outside, get in touch with District District authoritie authorities, s, who will take over the management and declare “Off-Site Emergency”. n. Control Control rehabilita rehabilitation tion of affec affected ted areas areas on cessation cessation of emergency emergency.. B. ADMINISTRATION AND COMMUNICATION COORDINATOR:
a. Liaise Liaise with with Chie Chieff and other other coord coordina inator tors. s. b. Inform and coordina coordinate te with Externa Externall agencies agencies and Mutual Mutual Aid members members of agreed agreed assistance. Direct them on arrival to the respective coordinators. c.
In case communicati communication on means means fail. Send Send messages messages to Mutual Mutual Aid members members / Emerge Emergency ncy departments. Coordinate with police in controlling the traffic and mob outside the premises.
d. Activate Activate the medical medical centre centre and mobilize mobilize medical medical team. Arrange Arrange ambulance ambulance and transfe transfer r casualties to hospitals. Also coordinate with police in case of fatalities. e.
Arrang Arrangee for head head coun countt at the assembl assembly y point points. s.
f.
Arrange Arrange procuremen procurementt of spares spares for fire fire fighting fighting and additional additional medical medical drugs drugs / appliance appliances. s.
g. Mobilise Mobilise Transp Transport ort as and when required required by various various coordinato coordinators. rs. Arrange Arrange to provide provide spark spark arrestors to emergency vehicles entering the premises. h. Monitor Monitor entry / exit exit of personn personnel el in the premis premises. es. Permit Permit only author authorized ized personn personnel el / vehicles inside the premises. i.
Control Control and disper disperse se crowds crowds from the the emergency emergency site. site. Regulate Regulate traff traffic ic inside inside the location. location.
j.
Arrange Arrange food, food, beverage beveragess and drinki drinking ng water water for all all those those involved involved in in execution execution of OSEP in case of the emergency e mergency prolongs.
k. Communicat Communicatee with relatives relatives of person’ person’ss injured injured / involved involved in fire fighting fighting activitie activities. s. l.
Arrange Arrange evacuatio evacuation n of premises premises as directed directed by Main Incident Incident Coordina Coordinator tor..
m. Coordinate Coordinate with civil authoritie authoritiess for evacuating evacuating public from the danger danger zone and arrange arrange for refreshments at the evacuation centre. C. SAFETY COORDINATORS:
a.
Ensure Ensure safe stoppage stoppage of the the operations operations;; switching switching of main instrum instruments, ents, shut shut off valves valves on product lines; and isolation of affected areas.
b. Demarcate Demarcate Danger Danger and Safe Safe Zones Zones by putting putting RED and GREEN GREEN flags. flags. c.
Mobilise Mobilise the the Fire Fighting Fighting crew crew and direct direct the Fire Fightin Fighting g operation operation..
d. Effectively Effectively deploy man power power,, both both internal internal and and external external.. e. Direct Direct and and utili utilise se the the Fire Fire Brigad Brigadee person personnel nel.. f.
Arrange Arrange the replacem replacement ent of various various Fire Fire Fighting Fighting squads squads with with Mutual Mutual Aid Aid / External External Aid members on need basis.
g. Ensure Ensure / maintai maintain n sufficie sufficient nt pressur pressuree in the the Hydrant Hydrant mains. mains. h. Assess Assess water level level in the the storage storage tank / reserv reservoir oir and plan plan replenis replenishment hment..
i.
Monitor Monitor the requir requirement ementss of Fire Fire equipment equipment and and coordinat coordinatee for procur procurement ement of of spares. spares.
j.
Arrange Arrange for flood lighting lighting of the the affected affected areas and dewaterin dewatering g of the Fire Fighting Fighting area, if required.
k. Arrange Arrange to remove remove and park the the tank lorries lorries (Bulk (Bulk & Packed) to a safer safer place, place, as necessary necessary..
FIRE AND TOXIC EMERGENCY ACTION PLANS
4.0 FIRE AND TOXIC EMERGENCY ACTION PLANS: INTRODUCTION:
The types of hazards in general are 1. FIRE 2. EXPLOSION 3. TOXI TOXIC C REL RELEA EASE SE (Chem (Chemic ical) al) The emergency arising due to fire and explosion are categorized under first categorized, which may cause material damage to the persons and property within the factory premises and which can be controlled effectively by using resources in the plant / units.
FIRE HAZARD:
Fire hazards in coal yard area, Diesel oil / Fuel oil storage area etc
EXPLOSION HAZARDS:
Explosion occurs hazards in boilers, turbines, digesters etc.
TOXIC RELEASE:
Particulars of the process and utilities with the significance in respect of Hazards. a.
In the the vari various ous stages stages of the the proc process essing ing..
b. b. In safe safe hand handli ling ng c.
In the the stor storage age of of the the chemic chemicals als in the the plan plantt
Information relating to hazards identification viz., The brief description of inbuilt preventive arrangements for those dangerous situations.
FIRE: What is fire?
Fire is a major hazard in any industry but is also a ver y necessary servant in the industry for imparting heat energy for the various process streams. As helpful as fire is, when property controlled, it can destroy both men and material when uncontrolled. Fire is a chemical reaction between oxygen and carbon in which heat and light energies are released. Three things are required before a fire can occur. These These are fuel, oxygen ox ygen and source of ignition. This comnination causing combustion is frequently referred to as the fire triangle. If all the three of these necessary elements are present in proper proportions, fire will occur. occur. If any one of the three is removed, fire is impossible. It is, therefore, important that we at all times prevent the triangle from becoming complete by eliminating at least one side. It is, however, more advisable to remove at least two sides, only the fuel and oxygen sides of fire triangle can be easily removed. Fuel may consist carbon or hydrocarbon. The fuel side of the fire triangle is removed by removing the combustible materials, or by preventing hydrocarbon from leaking or spilling into an atmosphere of air. This will prevent open fire. The oxygen side of the fire triangle is removed by preventing air from getting into system containing combustible materials, carbon or hydrocarbon. The ignition side of the fire triangle is controlled to some extent by proper guarding and a number of other mean, but those are so may sources of ignition that it must be assumed that this side of the triangle is always present.
Types of Fire: Fire have been classified into fire categories – A, B, C, D & E.
Fire involving ordinary combustible materials like wood, paper, textiles, etc., CLASS A: where one cooling effect of water is essential for the extinction of fires. CLASS B: Fires in inflammable liquids like Oils, Solvents, Paints, etc, where a blanketing effect is essential. CLASS C: Fires involving gaseous substances under pressure, where it is necessary to dilute the entering gas at a very fast rate within.
Fires involving metals like magnesium, alu minum, zinc, potassium etc., where CLASS D: the burning metal is reactive to water and which require special extinguishing media or technique. CLASS E:
Electrical Fires.
FIRE FIGHTING FIRST AID:
Fire fighting first aids comprise of water or sand buckets, portable fire extinguishers and hose reels. These from the first line of defence and are useful only in the initial stages of a fire. Water and sand should be used judiciously so as not to further harm the machinery / equipment. Portable fire extinguishers are mainly of 4 types. 1. Soda ac acid ty type 2. Foam t yp ype 3. Dry chem chemic icals als powd powder er (DC (DCP) P) and and 4. Carb Carbon on Diox Dioxid idee (CO (CO2) Soda acid type fire extinguishers are used for Class – A fires, form type fire extinguishers are used for Class – B fires, Dry Chemical Powder t ype fire extinguishers are used for Class – A, B, C & E fires. Special DCP fire extinguishers are available for Class – D fires. CO 2 type fire extinguishers are used for Class – A, B, C & E fires. One important thing about electrical f ires is that power should be switched off before fighting any electrical fire. What should be done when fire is detected?
1. As soon soon as fire fire is detected detected it should should be informe informed d on internal internal phone. phone. The The informatio information n to firemen should contain exact location of fire and the material, which has caught fire, etc. 2. Try to control control the fire fire by using using first first aid fire fighting fighting appliances appliances available available in the area. area. 3. Co. Operate Operate with with firemen firemen in extinguis extinguishing hing the the fire, when when they arrive arrive on the spot. spot. 4. Excessive Excessive crowd crowd can always always block block the access access of of fire fighting fighting squad, squad, therefore, therefore, help help in dispersing the crowd. Allow the fire fighters to function property and render assistance only when sought for.
5. Remember Remember that it it is easier easier to control control the fire fire in initial initial stages; stages; therefo therefore, re, try to control control fire by first aid appliances before the fireman arrives, so that it may not go out of control afterwards. The best policy polic y, however, is prevention is i s better than cure. Take necessary precautions before hand so that fire may not ignite at all. Most of the fires take place due to carelessness, lack of cleanliness and upkeep and wrong work practices. Electrical fires mainly originate from short circuit, overloading, loose connection, etc. Cutting and welding operations give rise to fire if proper precautions are not taken about combustible material in the vicinity. vicinity. Dust, broke, Oil grease, etc., scattered around the plant and equipment also cause fires many times. Throwing cigarette butts here and there are responsible for fire in good number of cases. In general, most of the fires can be prevented by cleaning, appropriate work practices and carefulness. Equipment available at Fire Fighting Emergencies: VLL fire brigade comprises of one fire officer and 12 firemen. It is equipped with a.
One ta tailer pum pump p
b. Wet type fire hydrant hydrant system system comprisin comprising g of about 60 hydrants hydrants main main spread spread various various section along with hose reels. The system is fed by water pond of 0.75 MGD capacity and remains charged all the ti me by running one pump. The fire pumps have following specifications. Pump power driven – Capacity 160 lit / sec. Delivery pressure 4 Kg to 6 Kg – 2 No. c.
Different Different types types of fire fire extinguis extinguishers hers and and sand buckets buckets are provided provided in in and around around the plant.
d. Fire Fire alarm alarm system system provid provided ed at at plant plant.. e. Asbe Asbest stos os fir firep epro roof of full full suits suits.. f.
Self Contain Contained ed Breathing Breathing Apparatuses Apparatuses (SCBA) with spare spare in cylinders cylinders of 20 minutes minutes duration.
Areas prone to fire hazards and inbuilt preventive arrangements.
1. Coal Coal Stor Storag agee Yard: ard:
Stock of coal is restricted to bare minimum, i.e., 10 days consumption and stock height is not allowed to exceed 10 feet. Fire hydrants are provided in coal storage area and hose reels also provided. 2. Diesel Oil / Furnace Oil:
Sufficient foam type fire extinguishers have been placed in the storage area. Fire department is adequately equipped with foam type t ype extinguishers for these types of fires. 3. Transformer / Switch Gears: Generally the transformers are loaded below their normal capacity only onl y. Transformers filled with non inflammable synthetic oil, have been provided with short circuit and over current fuse protection on primary side and breakers with over current and short circuit protections of individual circuits on secondary side, on which the load remains below the load remains below the breaker capacity. These transformers are given back up protection by mean of feeder breaker at power end. The 11 KV feeder breakers are provided with earth fault, over current and short circuit protections. Mineral oil filled transformers are provided with buccholaz rela y, switch gear protection on this primary and secondary side for over load earth fault and short circuit. Underground oil surfs have been provided with mineral oil filled transformers for drainage of oil in case of fire, without any spillage outside. Indication shave been provided on the transformers for temperatures and pressure level. The protection s ystem and transformer oil de-electric strength and insulation are checked periodically above all there is a regular system of checking of substation by shift engineers and electricians in each shift and by senior engineers at least once in a day da y for functioning or abnormality. Area wise distribution of fire extinguishers in VLL: List Enclosed.
The areas prone to explosion and special precautions taken in these areas are as follows: BOILERS:
Inspection, testing and maintenance of Boilers and accessories including safety valves and boiler mountings is being carried out as per statutory requirements annually and the boilers are hydraulically tested and inspected by b y the Inspector of Boilers once a year. year. Necessary instructions for Boiler Attendants: Following procedure should be adopted during e mergency for the safety of personnel and equipment in Boiler House. When the stea m pressure in boiler is increasing, following steps should be taken to control the same. a.
Coal feeding feeding should should be be reduced reduced or or stopped stopped if necessary necessary..
b. Air supply supply should should be reduced reduced or stopped stopped if necessary necessary.. c. Super Super heate heaterr outlet outlet drai drain n valve valve shoul should d be opene opened. d. d.
Water level level in boiler boiler drum should should be maintained maintained normal normal,, i.e., 3 ½ parts. parts.
If, after adopting the above procedure, you notice that steam pressure in boiler continues to increase due to some reason and various and safety valves are not operating on the set pressure,
you should operate the safety valves manually one by one to bring the boiler steam pressure within normal safe limits. i.
Super heater safety valve setting.
ii.
Header Psi
iii.
Drum Sa Safety valve se setting (l (left)
iv.
Drum Safety valve se setting (r (right)
Emergency Shut Down a. Sound Sound alarm alarm and unnece unnecess ssary ary pers personn onnel. el. b. b. Trips rips Oil Oil Pum Pump p c. Stop Stop fee water water to boile boilerr & drain drain up to to 8’ height height d. Trip Trip FD fan and and close outlet dumper dumper and and maintain maintain balanced balanced draft draft through through ID ID fan. e.
Continue Continue blank blank liquid firing firing to smooth smoother er the bed (K50% (K50% T.S.)
f.
Reduce Reduce steam steam press pressure ure as as rapid rapidly ly as possib possible. le.
g. Smoki Smoking ng is proh prohib ibit ited ed.. h. No outsi outsider der is perm permitt itted ed in guard guarded ed premi premises ses.. i.
Fire Fire of any type type is proh prohib ibite ited d
j.
Gas / Elect Electric ric weld welding ing / cuttin cutting g is prohib prohibited ited..
FIRST AID AND MEDICAL MANAGEMENT
FIRST AID AND MEDICAL MANAGEMENT: MANAGE MENT: SYMPTOMS: SKIN CONTACT:
1. Burning 2. Inflamm ammation 3. Burns Burns may may be very very pain painful ful,, painfu painfull bliste blisters rs 4. Prof Profou ound nd Damag Damagee to tiss tissue uess 5. Sta State of of Sh Shock Cold Seat – Pale Complexion Rapid and weak pulse Cold hands and feet Tendency to fait EYE CONTACT:
1. Water aterin ing g of of eyes eyes.. 2. Burnin Burning g sensa sensatio tion n in eyelid eyelidss and eyes. eyes. 3. Inflamm Inflammati ation on of eyes eyes ( Conj Conjunc unctiv tivitis itis ) 4. Diffic Difficulty ulty in in breath breathing ing and and rapid rapid breath breathing ing 5. Headache 6. Blui Bluish sh face face and and lip lipss 7. Salivation 8. Naus Nausea ea and and gid giddi dine ness ss 9. Musc Muscul ular ar weak weakne ness ss 10. Ulceration Ulceration of mucous mucous membranes membranes (nose) (nose) 11. 11. Acute pulmonary pulmonary edema 12. Chemical Chemical bronchitis bronchitis 13. Secondary Secondary chemical chemical pneumo pneumonia nia 14. 14. Deat Death h INGESTION:
1. Irri Irrita tatio tion n of mou mouth th and and thro throat at 2. Burnin Burning g sensat sensation ion of of lips, lips, mout mouth h and thro throat at 3. Pain Pain in swal swallo lowi wing ng 4. Ulcera Ulceratio tion n of of the the muco mucous us membra membranes nes 5. Edem Edemaa of of the the glot glotti tiss
6. Inte Intens nsee th thirst irst 7. Pain Painfu full abdom abdomin inal al cra cramp mpss 8. Burning Burning sensatio sensation n in the esophagus esophagus,, stomach stomach and and back of throat throat 9. Nausea Nausea and and vomi vomitin ting, g, occas occasion ionally ally of blood blood 10. Risk of perforation perforation of the the stomach 11. 11. Difficulty Difficulty in breath breathing ing 12. Shock Shock can can occur: occur: Cold Seat – Pale complexion Rapid and weak pulse Cold hands and feet Tendency to faint 13. Convulsion Convulsionss and and coma 14. 14. Deat Death h FIRST AID: SKIN CONTACT:
1. Remove Remove the the victim victim from from the affec affected ted area area immedia immediately tely.. 2. Take him him to the neares nearestt shower shower as early as possibl possible. e. 3. Remov Removee contam contamin inat ated ed clot clothe hes. s. 4. Wash skin skin with with large large amounts amounts of normal water water using using mild mild soap. soap. 5. Dust the the affected affected area area with powdered powdered Sodium Bicarbo Bicarbonate; nate; wash wash the affecte affected d area again again with normal running water. 6. Dry the the skin skin very gently using a clean clean and and soft soft towel. towel. 7. Do not apply apply oil or oily ointment ointment without without doctor’ doctor’ss advice. advice. Incase of burns burns (inflamm (inflammation, ation, blisters) 8. Apply Apply a dry dry ste steri rile le dre dress ssin ing g 9. Keep Keep the the victim victim warm using using a blanke blanket. t. 10. Immediately Immediately take take him to the nearest ho hospital spital EYE CONTACT:
1. Immediately Immediately remove remove the victim from the affect affected ed area. area. 2. Take him him to the the neare nearest st eye eye wash wash or show shower er.. 3. Flush eye eye immediately immediately with normal normal water water for at least least 15 minutes minutes or longer, longer, keeping keeping eye lids lids open. 4. Administer Administer two to three three drops drops of 0.5% solution solution of Pontoca Pontocaine, ine, or one drop drop of Benoxina Benoxinate te Novesine at 0.4% into the eye.
5. If the pain remains remains,, repeat repeat washing washing the the eye for for 15 minutes minutes or longer longer.. 6. Do not not try try to to neutr neutraliz alizee with with chemic chemicals als.. 7. Do not not use any oil oil or oily ointmen ointmentt with out doctor’ doctor’ss advice. advice. NOTE: The medical service will refer the victim to an ophthal mologist and inform him about the nature of the accident. INHALATION: a. If the the victim victim is conscio conscious us and and inhala inhalation tion is mild: mild:
i.
Remo Remove ve the the vic victim tim from from the the aff affec ecte ted d are areaa and and take take him him to well well vent ventil ilat ated ed area area..
ii.
Loosen the clothes and remo emove shoes.
iii.
Keep him warm using a blanket.
iv. iv.
Plac Placee the the pati patien entt on on his his back back with with head head and and bea beak k ele eleva vate ted. d.
v.
Rest is a must.
vi. vi.
If the the vic victim tim coug coughs hs a grea greatt deal deal,, make make his his inha inhale le a gau gauze ze pad pad soa soake ked d with with a lit littl tlee Ethyl Alcohol or a few drops of Ether.
vii. vii.
Coughs Coughs syrups syrups like like Hita Hitadri drine, ne, Coughr Coughrol, ol, Linctu Linctuss Code Codeine ine,, etc. etc.,, and and common common throat lozenges such as Vox, Vicks, Vicks, Halls, etc, can be given for smoothening the throat irritation.
viii. viii.
Milk Milk,, butte butterm rmil ilk, k, lime lime jui juice ce,, fres fresh h wate waterr may be giv given en..
b. If the victim is unconscious but breathing has not ceased:
c.
i.
Plac Placee the the pat patie ient nt in in a com comfo fort rtab able le posi positi tion on with with and and trun trunk k elev elevat ated ed to to 45” 45” position.
ii.
Remo emove dentures or partial plates. es.
iii. iii.
Keep Keep the the pat patie ien nt war warm m using sing a bla blan nket. ket.
iv. iv.
Admi Admini nist ster er medi medica call oxyge oxygen n unde underr low low pres pressu sure re usi using ng a pulm pulmot otor or or or simi simila larr type type of vital equipment.
v.
Do not give him anything to drink.
If breathing has ceased:
i.
Imme Immedi diat atel ely y remo remove ve him him from from the the af affect fected ed area area imme immedi diat atel ely y. Loosen his cloths. Lay him down on his stomach. Begin artificial respiration
ii. ii.
Imme Immedi diat ately ely admi admini nist ster er medi medica call oxy oxygen gen und under er low low pres pressu sure re usi using ng a pulm pulmot otor or or similar type of vital equipment.
iii.
Call a phys hysician im immediately. ly.
iv. iv.
As the the vic victim tim begi begins ns to to brea breath thee unla unlade ded d or to to mov move, e, lay lay him him dow down n with with his his bod body y raised and continue to administer medical oxygen.
v.
The The phy physici sician an will will keep keep the the vict victim im und under er medi medica call supe superv rvis isio ion n for for at leas leastt 48 48 hrs hrs as acute pulmonary edema or microbial infection may be caused.
INGESTION: a. If the the vict victim im is is cons consci ciou ous: s:
i.
Imme Immedi diat ately ely remov removee him him from from the the aff affec ecte ted d are areaa imm immed edia iate tely ly to a wel welll ven ventil tilat ated ed area.
ii.
Loosen his clothes.
iii. iii.
Ask Ask the the pati patien entt to dri drink nk cop copio ious us amo amoun untt of lime lime wate waterr or mil milk k of mag magne nesi siaa or calcined magnesia in water or table oil or fresh eggs.
iv.
Lay him down with his legs raised.
v.
Keep him warm using a blanket.
vi.
Rest is a must.
vii. vii.
If the victim’ victim’ss face face has become become blue, blue, lay lay him him down down on his back back with with head head turne turned d to one side.
viii. viii.
Admini Administe sterr medica medicall oxygen oxygen unde underr low low press pressure ure usin using g a pulmo pulmotor tor or simil similar ar type type of vital equipment. Do not administer mixture of oxygen and carbon dioxide (Carbogen).
ix. ix.
No atte attemp mptt shou should ld be made made to incl includ udee vomi vomiti ting ng..
b. If the victim is unconscious but breathing: i.
Lay him down on his back.
ii.
Loosen his cloths.
iii.
Keep him warm using a blanket.
iv.
Remo emove de dentures or or pa partial pl plates. es.
v.
Admi Admini nist ster er medi medica call oxy oxyge gen n und under er low low pres pressu sure re usi using ng a pulm pulmot otor or or simil similar ar type type of vital equipment. Do not administer carbogen.
vi.
Do not give him anyt nything to drink.
c. If brea breath thin ing g has has ceas ceased ed::
i.
Imme Immedi diat ately ely lay him down down and and beg begin in arti artific ficia iall res respi pira ratio tion n or mout mouth h to to mou mouth th resuscitation.
ii.
Loosen his cloths.
iii.
Keep him warm using a blanket.
iv. iv.
Cont Contin inue ue to to admin adminis iste terr medi medica call oxyge oxygen n unde underr low low pres pressu sure re usi using ng a pulm pulmot otor or or or similar type of vital equipment till the victim begins to breathe unladed.
Therapy for specific physiological disturbances – For the guidance and attention of medical profession. PULMONARY EDEMA:
1. Admini Administe sterr 60 to to 100% 100% oxy oxygen gen at at 6 lit lit / min. min. 2. Intermitten Intermittentt positive positive pressure pressure breathing breathing appara apparatus tus set to deliver deliver positive positive pressur pressures es of 515 cm of water in the respiratory cycle is valuable in reducing the formation of edema. 3. Steroid Steroid therapy, therapy, given early early is effective effective in prevent preventing ing or alleviating alleviating pulmona pulmonary ry edema. edema. 4. The use of of diuretics diuretics and antibioti antibiotics cs should should be considered considered to reduce reduce edema edema and protectio protection n against secondary pulmonary infection. BRONCHOSPASM:
1. The exposure exposure is associated associated with acute acute symptomato symptomatology logy requiring requiring supporti supportive ve therapy. therapy. Early treatment is the most effective. 2. Broncho-d Broncho-dilators ilators nebuliz nebulized ed into the intermit intermittent tent positive positive pressur pressuree gas steam are are often beneficial. 3. Two effe effect ctiv ivee dru drugs gs are: are: Isoproterenol hydrochloride Cydopentemine hydrochloride and aludrine. The commonly employed single treatment dosage for each drug is 0.3 cc. This may be altered according to clinical needs. INCREASED MUCOUS SECRETION:
1. Positive Positive pressur pressuree treatment treatment tends tends to suppress suppress the the secretion secretion of mucous. mucous. 2. Nebulized Nebulized detergents detergents assist assist in the thinni thinning ng of mucous. mucous.
BOARD OF DIRECTORS S.No.
1.
2.
Name of Director
Mr.Santosh Varalwar
Designation
Land line No.
Chairman & Managing Director
040- 27170006 / 05
9849058361
Vice - Chairman
040- 27170006 / 05
9849058362
Mr.Subhash Varalwar
Director-Operations 1.
9849046755
Mr.S.Raghunandhan
Factory Manager 2.
Cell No.
Mr.F.P.Preston
040- 27065946 & 08458- 274484
9885748674
