P FD File

ON SITE EMERGENCY PLAN
As per
Schedule 6 of the Maharashtra Factories
(Control of Industrial Major Accident Hazards) Rules, 2003.
AARTI INDUSTRIES LTD.

Plot No. A-94/1 & A-94/1/1, MIDC, TTC Indl Area,
Navi Mumbai, Maharashtra
October 2019.
ON-SITE EMERGENCY PLAN
CONTENTS
PREFACE
ON SITE EMERGENCY PLAN
CHAPTER- 1: ORGANIZATION INFORMATION
CHAPTER- 2: SITE DEMOGRAPHY
2.1 DESCRIPTIONS OF DISTRICT MAP
2.2 SITE PLAN
2.3 SITE LAYOUT PLAN
CHAPTER- 3: ROLES AND RESPONSIBILITY
3.1 ROLES AND RESPONSIBILITY OF EMERGENCY RESPONSE PERSONNEL
3.1.1. Action Plan for Site Main Controller (SMC)
3.1.2. Action Plan for Incident Controller (I.C)
3.1.3. Roles & Responsibility of Deputy Incident Controller
3.1.4. Responsibilities of Night Duty Officer
3.1.5. Action Plan for Safety Department
3.1.6. Emergency Response Team (ER)
3.1.7. Emergency Control Centre (ECC): In-charge
3.1.8. Communication Officer (C.O)
3.1.9. Administrative Services
3.1.10. Action by Security Officer (S.O)
3.1.11. Action by Maintenance Department
3.1.12. Action plan for Nodal Officer of HR Department at Assembly Point
3.1.13. Role & Responsibility of Essential Employees (Workers)
3.1.14 Role & Responsibility of Key Personnel
3.2 EMERGENCY CONTROL CENTRE
3.3 ASSEMBLY POINTS
CHAPTER- 4: EMERGENCY MANAGEMENT PLANNING
4.1 POSSIBLE HAZARDOUS SCENARIO
4.2 PRE INCIDENT PLANNING
CHAPTER-5: COMMUNICATION ARRANGEMENTS
5.1 RAISING THE ALARM
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5.2 DECLARING THE MAJOR EMERGENCY
5.3 TELEPHONE MESSAGES
5.4 RUNNER
5.5 COMMUNICATION OF EMERGENCY
5.6 TO KEY PERSONNEL OUTSIDE NORMAL WORKING HOURS
5.7 TO THE OUTSIDE EMERGENCY SERVICES AND THE AUTHORITIES
5.8 TO NEIGHBOUR FIRMS AND THE GENERAL PUBLIC
CHAPTER- 6: FIRE FIGHTING AND OTHER ARRANGEMENTS FOR EMERGENCY
6.1 AVAILABILITY OF FIRE FIGHTING FACILITIES
CHAPTER- 7: MUTUAL AID ARRANGEMENTS
CHAPTER- 8: INFORMATION ON THE PRELIMINARY HAZARD ANALYSIS

8.1 TYPES OF ACCIDENT
8.2 SYSTEM ELEMENTS OR EVENT THAT CAN LEAD A MAJOR ACCIDENT
8.3 HAZARDS
8.4 SAFETY RELEVANT COMPONENTS
8.5 LOCATION OF DANGEROUS SUBSTANCES
CHAPTER- 9: DESCRIPTION OF HAZARDOUS CHEMICALS AT PLANT SITE

9.1 RAW MATERIALS STORAGE
9.2 OTHER HAZARDS & CONTROLS
9.4 DRUMS EXPLOSION
CHAPTER-10: MAXIMUM CREDIBLE ACCIDENT SCENARIO & CONSEQUENCES

ANALYSIS
10.1 FIRE IN PLANT

10.2 FIRE IN BOILER AREA
10.3 EXPLOSION
CHAPTER- 11: EMERGENCY DUE TO NATURAL CALAMITIES

11.1 TYPES OF NATURAL CALAMITIES & ITS ACTION PLAN:
CHAPTER- 12: INTEGRATION OF ON-SITE EMERGENCY PLAN WITH DISTRICT OFF-SITE

PLAN
12.1 PURPOSE OF THE OFF SITE EMERGENCY PLAN:

12.2 SCHEMATIC DIAGRAM SHOWING ACTION FROM INCIDENT PLACE TO
STATE LEVEL GROUP
12.3 ROLES AND RESPONSIBILITIES OF STAKEHOLDERS INCLUDING
EXTERNAL AGENCIES
12.4 IMPORTANT EXTERNAL TELEPHONES NUMBERS
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12.5 RECOVERY, RECONSTRUCTION AND REHABILITATION
ANNEXURE - 01 MOCK DRILL OBSERVATION SHEET

ANNEXURE – 02 KEY PERSONS
ANNEXURE – 03 EMERGENCY RESPONSE & EVACUATION GUIDE OF HAZARDOUS
CHEMICAL
ANNEXURE –04 POLLUTION CONTROL ARRANGEMENT
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PREFACE
ON SITE EMERGENCY PLAN:
It is impossible (economically) to reduce the residual risk to zero. But by conducting risk
assessment & consequence evaluations it is possible to determine the location of
emergency, average frequency of occurrence of hazardous events, the distance to which
the damage can be hazardous. Accordingly, the plan to handle the emergency can be
prepared. Thus, this makes the emergency totally known and hence easy to handle.
The emergency handling can be planned & the personnel involved in handling emergency
can be trained properly. The emergency handling/countering appliances can be kept
ready at required locations.
The people not involved in handling emergency but are possible to be engulfed in the
accident, should be trained how to react for this emergency after receiving the intimation.
This also helps to make control measures more effective in coping with operational
emergencies or emergencies of fire, explosion, storm, flood, and civil commotion and / or
any situation which, if uncontrolled, could result in extensive damage in the factory. The
intent of this plan is to provide an organizational setup which will allow the most effective
use of available resources of M/s. Aarti Industries. Ltd., Navi Mumbai, in an attempt to
limit damage to personnel and plant, and speed up repairs of damage suffered. The
emergency organization is manned entirely by the company employees, and each
individual who is a part of the organization has been given a specific responsibility. The
purpose of this plan is to familiarize each and every employee with his specific function
during different emergencies and to give the employee a total picture of the emergency
organization so that he clearly understands the purpose and importance of his role.
CHAPTER- 1: ORGANIZATION INFORMATION
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Aarti Industries Ltd.

Full Name & Address of the
company: Plot No. A-94/1 & A-94/1/1, MIDC, TTC Indl Area,
Navi Mumbai, Maharashtra.

occupier :
Mr. Kirit Mehta

Manager : Mr. Shrikant Kamble
Maximum workers at a time

Name of the shift
Male Female Total
General (G) 174 194

20
First (A) 22 05 27
In “workers” include all
employees contract
Second (B) 29 00 29 workers, trainees,
apprentices, etc.
Third (C) 00 00 00
Total Workers 225 25 250
First person to be contacted in case of emergency:
First person to be contacted in case of emergency

Sr. No.
Contact No.
Name & Designation Place of availability
1. Mr. Shrikant Kamble Office 9819934076
2. Mr. Ramprasad Kapse Office 6359771057
3. Mr. Vijay Pandey Office 6359771058
CHAPTER- 2: SITE DEMOGRAPHY
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2.1 DESCRIPTIONS OF DISTRICT MAP
DETAILS OF COMPANY:
M/s. Aarti Industries Limited is a fast growing basic organic chemical manufacturing
group. The group has several small, medium and large scale industries at various
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locations. The locations include Vapi, Sarigam, Jhagadia, Dahej, Kutch etc. in Gujarat and
Tarapur at Maharashtra. Aarti Industries Limited is planning to start R&D facilities centrally
located at Mahape. One of the important tasks of R&D is finding green chemistry routes
for existing as well as proposed products. After developing the products, the group
requires pilot scale facilities at pilot scale scaling of operation is carried out, plant
parameters are established and product approvals are undertaken. M/s. Aarti Industries
Limited will be a pilot scale facility of M/s. Aarti Industries Limited here various facilities will
be established to carry out multi facility unit operation.
Once products are optimized for manufacturing process and market, the technical know
how is passed on to sister concern group companies and at M/s. Aarti Industries Limited
new products will be started. Thus the project proponent has proposed to carry out various
products based on the above unit operations. The names of products may get changed at
several intervals.
Adjoining Properties
North side Fabrication Company
East side MIDC Road
West side SKC Chemie Pvt Ltd.
South side Closed Factory
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2.2 SITE PLAN
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2.3 SITE LAYOUT PLAN
M/s Aarti Industries Limited will be a pilot plant (R&D) factory located at Khairane MIDC,
Navi Mumbai. The pilot plant (R&D) is a member of Aarti Group of Industries whose other
manufacturing units are also located Vapi, Tarapur and other places.The plot area of
occupied land is having total area of 6576 sq m.
Address: Aarti Industries Limited,

Plot No. A-94/1 & A-94/1/1, TTC Indl.
Area, Khairanae MIDC,Navi Mumbai.
The Unit consists of various Departments/ sections/ areas, are expressed as below:
❏ Main R&D Lab
❏ Pilot Plant
❏ D.G.House
❏ Underground water tank
❏ Transformer area
❏ Boiler Area
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CHAPTER- 3: ROLES AND RESPONSIBILITY

Emergency
An emergency is an abnormal event, which could result in danger to personnel, property
and the environment. It could be due to fire, Explosion, Heavy spillage of hazardous liquid,
toxic gas release etc.
CLASSIFICATION OF EMERGENCIES
Emergencies can be categorized into three broad levels on the basis of seriousness and
response requirements, namely:
Level-1: Plant/Area of the plant
The emergency situation arising from any section of any particular plant/area which is minor in
nature, can be controlled within the affected section itself with the help of in house resources
available at any given point of time. The emergency control actions are limited to level-1
emergency only.
Level-2: Affecting more than one plant within the facility/complex
The emergency situation arising in one or more plant which has the potential to cause injury or
damage to property, environment within the affected plant or to the nearby plant/area. This level
of emergency situation will not affect the surrounding community beyond our facility.
Level-3 Affecting Neighboring Area
The emergency situation described in level-2 which by virtue of its consequences will spread and
affect nearby community outside the facility boundary or complex.
Note: Level 1 and Level 2 shall normally be grouped as onsite emergency and Level 3 as
off- site emergency.
MODE OF EMERGENCY
Man made Natural Calamities Extraneous
Leakages/ Spillage Earthquake Riots/Civil Disorder
Fire Flood Terrorism
Explosion Outbreak of Disease Sabotage
Failure of Critical Control system Lightning & Cyclone Bomb Threat
The On-site emergency plan deals with measures to prevent and control emergencies
within the factory and not affecting outside public or Environment.
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The Off-site emergency plan deals with measures to prevent and control emergencies
affecting public and the environment outside the premises.
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Emergency Organization Chart
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3.1 ROLES AND RESPONSIBILITY OF EMERGENCY RESPONSE PERSONNEL
3.1.1. Action Plan for Site Main Controller (SMC)

On receiving information on Incident / Accident or emergency, SMC will carry out the
following activities:
1. Reach to the incident place and assess the situation with IC.
2. Decide the level of emergency and declare emergency accordingly.
3. Ensure the mobilization of emergency response according to scale of emergency.
4. Ensure the constant availability of Incident Controller, Key Persons and other
required persons at the site of incident.
5. Ensure that the information will reach to the Head Office.
6. Ensure necessary shut down of other related plants to control the emergency
situation.
7. Ensure adequacy of fire fighting and rescue aid at site to control the incident.
8. Ensure that all statutory authorities (such as District collector, local crisis group,
Director, Industrial Safety & Health, PESO department, MPCB, Boiler, Electric
Inspector, as applicable are kept informed about the incident.
9. Ensure that in case of scale of emergency turns to off site, mutual members, local
crisis group/ District crisis group will be called.
10. Ensure that injured or casualties are receiving adequate attention for medical
treatment and their relatives are kept informed.
11. Continuously review the possible development of emergency and rescue
operation.
12. Ensure validated press release about the incident for information to the public.
13. If the scale of emergency escalates to off-site level-3, he will ensure that
information is passed on to the public likely to be affected in the area.
14. Ensure that victims get rehabilitation, if required.
15. On controlling situation and attending the normalcy, he reviews the situation with
IC and Safety Head then he will declare the control of emergency (All Clear).
16. Constitute the internal investigation committee to investigate the incident,
recommendations, and corrective measures to prevent re-occurrence of incident.
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17. Before restarting the plant, he ensures environment clearance from the
Environment expert for safe restarting and from Director, Industrial Safety & Health
as required.
3.1.2. Action Plan for Incident Controller (I.C)
(Head of respective department)
Head of Department of Incident Site department has to carry out all functions as incident
Controller at scene of Incident. Further, He will hold the position of SMC, till SMC will take
over. IC has to perform the following duties, along with other duties as directed by SMC
will perform the role as Incident Controller till the arrival of Site main controller.
1. Immediately rush to emergency site.

2. Ensure that emergency information passed to the all emergency services i.e.
Safety Department, Engineering department, Security Main Gate, OHC Centre, for
responding action at incident site.
3. Ensures that all steps are taken for mechanical and electrical isolation to control
the situation.
4. Till Site Main Controller has reached at the scene, Incident Controller takes the
responsibility of his post, and if necessary directs safe shut down of plant, declare
emergency and evacuated people. Further, he will direct ECC to inform Fire
Brigade, Police, Medical Services, Mutual Aiders, etc. giving details of incident for
required helps.
5. Ensures that all key personnel will be informed and available at site.
6. Ensures coordination among all working agencies on the site.
7. Ensures that persons available at site are deployed for emergency handling such
as Fire Fighting, Causality searching, rescue and first aid.
8. Ensures the availability of equipments, machineries and devices available in the
unit is mobilized at site for lifting and shifting of material from the scene of an
emergency site.
9. Ensure that the affected area is barricaded and evidence of incident are retained
at site.
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10. Suitable appropriate decision for the operation / running of the plant.
11. Ensure to post the person at strategic location to guide the route of incident to the
out-side agencies/authority.
12. Ensure that all non-essential workers/staff of the affected area are instructed to go
to respective assembly point / shelter and areas are searched for casualties.
13. Update about the happening on site to SMC.
14. On withdrawal of emergency and getting clearance from SMC, he will initiate the
start-up procedure of plant.
15. Ensure to preserve all documents, relevant evidence etc. for subsequent
investigation & inquiry.
16. Minimize damage to property, environment and material loss by taking necessary
action within control.
17. Direct all operations within the affected area giving priority to safety of personnel.
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3.1.3. Roles & Responsibility of First, Second & Third Shift in Charge (Deputy
Incident Controller)
The first direct response comes from the personnel at the location of the incident.The Shift
in-charge will make the first response to the incident. He will: Raise the alarm/warning.
Activate fixed protection equipment (e.g. sprinkler systems, water curtains, fire hydrants &
fire monitors); Carry out initial rescue and firefighting, employing appropriate combat and
protective equipment; Stop or minimize fuel flow; Inform security (for traffic control), fire
station and other site areas about the situation;
Make the process equipment involved in the event safe by isolation of source of leakage,
depressurizing and/or shutting down, as necessary in consultation with IC. Request
assistance from others (e.g. engineering, medical).
3.1.4. Responsibilities of Night Duty Officer
Act as Incident Controller for the time being. As soon as becomes aware of the emergency
and its location, he will proceed to the scene. Assess the scale of the incident and direct
operations within the affected areas. He/she will contact and inform the Site Main
Controller and Incident Controller immediately. Till their arrival he will continue to perform
their duties. Contact the shift supervisor to act as Deputy Incident controller and guide
Security Officers for communicating to key responsible persons. In an emergency,call the
Medical Officer to the plant.
Other staff e.g. ERT with designated responsibilities will act as instructed.
In case of a fire/explosion NDO has to assess the situation and has to initiate fire fighting
activities. He should take the help of the Shift supervisor (IC as per our procedure) and in
his absence his second line (over phone) for emergency mitigation. One Electrician or fitter
should be posted near the fire hydrant pump house. Unit Head and his second line to be
alerted (security should be used for conveying message). Once the emergency is
mitigated, area to be monitored (even if it is not an on-site emergency) before re entry. In
case of a toxic release, evacuation to be done in a direction perpendicular to the wind
direction. The help of ERT/plant to be taken for leakage arresting. In case of a spillage,
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suitable neutralizer/absorbent to be used after consulting the IC and also after referring
the MSDS.
3.1.5. Action Plan for Safety Department
Safety Department has to perform major role for emergency mitigation and responding
actions. The Safety department employees present at site will undertake the following
actions:
Action Plan for Manager (EHS)
On getting information on emergency, he will rush to site. On reaching site, Safety
Manager will evaluate the situation with IC and SMC discuss handling and controlling
operations. Ensure that adequacy of fire fighting and rescue operation during action.
Ensure that all trapped persons are safely rescued and if necessary given proper medical
treatment. Monitor the situation and give guidance for response action to his team
members.
Ensure adequacy of resources to tackle the emergency. If required more resources, than
after consulting with IC & SMC, he will call other help from out-side resources from mutual
aiders and TTC Industrial Association.
Ensure experienced and trained persons are properly and adequately posted at various
locations to handle the emergency effectively.
Monitor the effect of the incident on the nearby plants & facilities.
Appraise the IC/SMC on Fire / Gas Leak, evacuation of persons, hazards of chemicals
and on emergency situation.
Coordinate & support the internal investigation committee.
Ensure that the environment will be properly monitored before environment clearance for
re-starting of plant.
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Ensure reporting to the statutory authorities in the format as prescribed.
Monitor the run off water route and Effluent Treatment Plant operations.
Monitor the Fire Water Tank Level and operation of the Fire pumps.
3.1.6. Emergency Response Team (ERT):
Emergency Response Team (ERT) is attached with safety department, working under
available Safety Officers at site.
1. Rush to the site/incident place immediately on getting information and survey the
area, accordingly give feedback to control room/ IC / Manager (SHE) and start
responding action by selecting and using proper fire fighting equipment and gas
masks or respirators if required.
2. Communicate fire fighting progress and details on additional resource needed to
IC from time to time.
3. Arrange adequate and proper fire fighting equipments as per need at the incident
place. They will also close valves of gas and fuel lines, if any, after consultation
with IC / Safety Head.
4. Carry out rescue operations for injured/trapped person and call vehicles to shift
them for hospitalization.
5. Ensure during the search, no person is left inside.
6. Ensure route of fire tender will be free from obstacles.
7. Confirm the control of the incident and accordingly inform Manager (SHE) and IC.
8. Arrange to collect all fire fighting equipment, instruments, articles, used or unused
from the site after the incident is over.
9. Coordinate for removal of water logging due to fire fighting at site.
10. On getting clearance from IC, SMC or Manager (SHE), he and his staff can leave
the incident place.
3.1.7. Emergency Control Centre (ECC): In-charge
1. Ascertain information on type of incident, involvement of chemicals, exact location,

involve department, person presents etc. In-charge will confirm such details from
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Head of respective department; then, pass on the information to other designated

person.
2. Communicate to security to report at site immediately.
3. Simultaneously, In-charge will pass on information to Manager (SHE) and SMC.
4. Coordinate with Head of Department at incident place, constantly.
5. On getting message to declare the emergency accordingly, ensure to sound the
siren immediately and intimate to IC, Manager (SHE), and SMC.
6. Communicate to the control room of local crisis group, VIA and fire brigade, as
instructed.
7. Convey the message for rescue of trapped persons, requirement of ambulance
etc. as instructed by IC/SMC.
8. Communicate the requirement of equipment, man power, vehicles etc. to mutual
aiders as instructed by IC/SMC.
9. On arrival of mutual aiders, In-charge ensures coordination with own fire crew and
other related matters.
10. Maintain communication system in working and efficient condition.
11. Arrange chronological records on the emergency.
3.1.8. Communication Officer (C.O)
1. The experienced, senior person shall be selected and posted for

communication purpose at ECC.
2. Ensure the board keeps free to receive incoming call without disturbance and
inform pass/divert/convey to IC, ECC or SMC as per calling person.
3. Keep ready essential emergency telephone numbers with contact person. He
will maintain notes of all communication with time measurements.
4. Convey the short message to Head of Department, Key persons, Essential
workers, and all concerned as directed by SMC/ IC.
3.1.9. Administrative Services
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(A) Action by Head (HR)

1. Keep constant touch with the SMC and he will keep liaison with official of labour
dept., Office of Director Industrial Safety & Health, Police Authority, Notified Area
Authority, local authorities and relatives of affected person, trapped, injured or
admitted to the hospital inside and outside, further he will keep ready the local and
permanent address of such persons and their relatives.
2. Keep liaison with Explosive Department, MPCB and Boiler Inspector.
3. Ensure to post an experienced and senior person for recording presence and
missing, injured, trapped, dead person’s name, if so, and HR will prepare the list
and report to the SMC.
4. Ensure the counting of total number of persons at site, list of missing/trapped
person, injured person and fatality. Further, he will ensure to convey the message
to the relatives of injured or death.
5. Arrange liaison work with hospital Authorities, admitted injured person and their
relatives.
6. If emergency extends for prolong period, then HR will arrange for water and food
as per prevailing situation under consultation with SMC.
7. Arrange manpower and guide evacuation of the surrounding people to safe
shelter by use of vehicles in consultation with SMC.
(B) Action by Head (ADMN.)
1. Ensure to coordinate with the concerned department in respect of help and

assistance of manpower, transport, financial need, procurement of emergency
equipment or medicine after consultation with SMC and Safety Head. He will keep
constant touch with the SMC for development of situation.
2. Recall the personnel off duty during emergency period and post them to carry out
specific duties in consultation with SMC and Safety Head.
3. Ensure that the emergency work will not suffer due to administrative control.
4. Ensure that the suitable information is given to the media as approved by SMC.
3.1.10. Action by Security Officer (S.O)
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1. Immediately rush to site to take cognizance of situation for mobilizing the

resources.
2. Arrange to cordon the incident place by deputing more security guard &
mobilize additional search force for help.
3. Control the traffic by deputing additional security guard & Prevent
unauthorized entry to the factory.
4. Arrange security guards for firefighting and rescue operation.
5. Arrange proper parking to the incoming vehicles without obstructing
movement of emergency vehicles and ensure that escaping route shall not
be disturbed by any vehicle.
6. Arrange security guard at Assembly Point & help to nodal officer.
7. Arrange additional manpower for evacuating and shifting person from
assembly point to safe shelter, after consultation with SMC, Head Safety.
8. Arrange to operate PA system for warning and alerting surrounding people,
villagers for evacuation and shifting to safe shelter as directed by SMC.
9. Ensure that the evidence of the incident shall not get dismantled.
3.1.11. Action by Maintenance Department
On getting information on emergency, head of department will immediately contact SMC/

IC and as per direction by SMC, arrange engineering services related to mechanical,
Electrical, instrumentation.
1. Mobilize more maintenance Staff for help & repair as asked for.
2. Mobilize more man power for electrical/ instrumentation work.
3. Direct concerned operatives to provide extra lighting or isolation of electric
supply as per need.
4. They will report to Incident Controller.
3.1.12. Action plan for Nodal Officer of HR Department at Assembly Point
1. Prepare and maintain the records of persons present at assembly point, evacuated
persons, person not tracked out at site in the format.
2. Collect the attendance sheets from the contractors and ensure that all personnel
reported duties are evacuated safely at the assembly point.
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3. All nodal officer posted at assembly point shall coordinate among themselves for
re-confirmation/re-verification of total man power evacuated from the area.
4. In affected and vulnerable plants, all affected workers shall be evacuated to a
specified assembly point by Nodal Officer.
5. In case of a person who is missing or not traceable at incident site and not reported
to the assembly point, the nodal officer will immediately inform to SMC, IC and
Head HR.
6. Ensure that the list of relatives or care taker of such person, with the contact details
will be collected and communicated to the concern.
7. Nodal officer will prepare and maintain the records of injured/ affected /
hospitalized/ under treatment / person on leave, in addition to attendance sheet.
3.1.13. Role & Responsibility of Essential Employees (Workers)
They are a task force of trained workers or expert teams to carry out specific job or work
at the time of emergency and perform the duty under guidance of Incident Controller/Site
Main Controller.
Essential Employees Teams are:

(a) First Aid Team
(b) Emergency Response Team
Such work will include:

1. Start Fire fighting, gas leak and spill control till a plant Fire Brigade takes
the charge.
2. Shutting down plant and making it safe.
3. Emergency engineering work e.g. Isolating equipment, materials, process,
providing temporary by-pass lines, safe transfer of substance, urgent
repairing or replacement, electrical work etc.
4. Provision of emergency power, water, lighting, instruments, equipment,
materials etc.
5. Movement of equipment, special vehicles and transport to or from the scene
of the incident.
6. Search, evacuation, rescue and welfare.
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7. First – aid and medical help.

8. Information to surrounding factories and the public as directed by the site
Main Controller.
9. Assistance at communication centre, casualties, reception centre, liaison
with police etc.
10. Any special help required.
3.1.14 Role & Responsibility of Key Personnel
1. The key personnel shall be available at any time on duty or on call when off or on
holiday. The Role of key personnel is to carry out the instructions given by site Main
Controller at the time of emergency. The key personnel shall be from the experienced and
trained managerial staff. Generally, key personnel will be from senior levels & perform the
major work on advice made by the site main Controller.
2. Key Personnel will be the second line in command for all the Plants & Departments
including Non technical Departments. Plant & Department Heads will be acting as
Coordinators to the SMC. Following Plants Departments will take action:
● R&D Manager
● Safety Manager
● Security Officer
● Administrative
● HR
● Engineering
● QC
● Purchase & Contract
● Finance
3. The role of Key Personnel will be to implement the decision given by their HODs
based on prime responsibilities of that particular plant/ Department as defined in this plant.
4. Key Personnel will report at ECC.
5. All the coordinators will report at incident site in safe zone.
3.2 EMERGENCY CONTROL CENTRE
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The emergency control centre (ground floor control room) is the place from which the
operations to handle the emergency are directed and coordinated. The site main controller,
key personnel and senior officers of the fire, police, DISH, district authorities and
emergency services will attend it. The centre should be equipped to receive and transmit
information and directions from and to the site incident controller and areas of the works
as well as outside. It should also have equipment for logging the development of the
incident to assist the controllers to determine any necessary action.
In addition to the means of communication, the centre should be equipped with relevant
data and equipment which will assist those manning the centre to be conversant with the
developing situation and enable them to plan accordingly.
It should be sited in an area of minimum risk and close to a road to allow for ready access
by a radio-equipped vehicle for use if other systems fail or extra communication facilities
are needed.
For large sites or where Fire may occur might be anticipated, consideration should be
given to setting up two control centers to ensure, so far as is possible, that one will be
available for use, should the other be disabled. If necessary the police will assist to set up
an emergency control center remote from the works.
The center should therefore contain:

1. An adequate number of internal telephones.
2. An adequate number of external telephones. It is strongly recommended that at
least one should be ex-directory or capable of use for outgoing calls only. This will
avoid the telephone switchboard being overloaded with calls from anxious
relatives, the press etc. the least telephone directories with a separate list of
important numbers.
3. Plans of the factory should show:
a) Areas of large inventories of hazardous materials including tanks, reactors, and
drums, compressed gas cylinders.
b) Sources of sirens and safety equipment including fire, explosion, and Toxic gas
Release, Heavy Spillage of Hazardous & Toxic Chemicals.
c) Stocks of other fire extinguishing materials.
d) The fire - water system and additional sources of water.
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e) Site entrances and road system, updated at the time of the emergency to indicate
any road that is impossible.
f) Company assembly point, shelters, lunchroom and canteen.
g) Casualty treatment centers, first aid centers and ambulance room.
h) Parking points, rail sidings and visitors room.
i) Location of the factory in relation to the surrounding community.
4. Additional plans which may be marked up during the emergency should show:
a) Areas affected or endangered within the factory.
b) Surrounding areas, population and other environment likely to be affected due
to fire wind speed recorders and ready computer models (risk counters) based
on prevailing wind direction, velocity, weather conditions and other parameters,
will be very useful for quick judgment and evacuation of those areas.
c) Areas where particular problems arise.
d) Area evacuated and safe routes for escape.
e) Deployment of emergency vehicles and personnel.
f) Other relevant information.
5. Nominal roll of employees, work permits, MSDS, gate entries and documents for
head count or access to this information. Employee's blood group information and
addresses will also be useful.
6. Note pads, pens, pencils, rubber and stationery to record all messages received
and sent by whatever means.
7. Note copies of this on-site emergency plan i.e. updated full text including all
information from this, some vehicles and messengers (runners) should be kept
ready at the centre.
8. Torches, umbrellas, raincoats and some extra sets of gas detectors, explosive
meters and personal protective equipments.
3.2.1 Details of the emergency control centre:
Location of the Centre: Control Room
Page26
Person who Its period of

Sr. will handle / operation
Item Kept in the Centre Nos. of Quantity Notes
No operate this
item Last Present
1 2 3 4 5 6 7
Copy of On Site Emergency

1 1 - - -
Plan
2 List of Emergency Phones 5 - - -
3 Personal Protective Equipment 30 - - -
4 Torch 01 - - -
5 Umbrella 01 - - -
6 M. S. D. S. 1 Set - - -
7 Process Chart 1 - - -
8 Storage Details 1 - - -
9 List of Essential Workers 1 - - -

Site Main
10 List of Key Personnel 1 Controller, - - -
ECC,
Maps & Charts for Emergency Key
11 Entry route, escape route, 2 Persons, etc - - -
Parking etc
Other Documents and Materials

12 3 - - -
as required for Emergency
Emergency equipments
13 4 - - -
Suppliers, Details
Medical Details, Hospitals.

14 Doctors with name & Contact 2 - - -
Number
Water Resources, Material

15 2 - - -
aiders etc Details
List of Government
16 Agencies/Local/Press 2 - - -
Agencies with phone No.
Page27
3.3 ASSEMBLY POINTS
EMERGENCY ASSEMBLY POINTS
In case of emergency such as fire, non-essential persons and injured persons are
evacuated from the affected area to the safest area, i.e. at the assembly point. Assembly
point is the least affected by down wind direction and near to the road. The senior officer
will be the person in charge of this point. The capacity of assembly point is to
accommodate about 100 persons.
Non essential personnel shall assemble at Emergency Assembly Point as announced by

Incident Controller. During handling the emergency if more work forces are required then
from assembly point non-essential persons will be called as per the requirement, it will be
decided by SMC.
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At the time of Emergency
Person in Charge
Assembly Point Location
Place of Availability
Name
In the Factory
1 Security person At main gate

Near main gate
2 Security Back Gate

Back Gate
Page29
CHAPTER- 4: EMERGENCY MANAGEMENT PLANNING
INTRODUCTION
Pre - Emergency means the preparatory stage. It is the planning period and it should come
out to ensure that the plan is contained with required provisions and facilities to handle
and contain the emergency successfully. The unit has to consider the worst possible
scenario for emergency while planning. Further, the unit has to develop and maintain the
essential facilities, so that emergency can be controlled to minimize the damages in
shortest period by optimising the use of existing resources.
The awareness and preparedness shall be created amongst all the persons, for the
hazards involved due to the storage and handling of hazardous chemicals in the premises
and what response infrastructure is available with the complex. However, existing
preparedness and adequacy of resources shall be reviewed periodically, considering
probable worst case scenario situation.
The structure of the plan may vary depending on the number of employees, materials,
process, and availability of resources, location of site, size and complexity of the unit. It
should work out a plan with possibilities of various emergencies likely to arise within unit.
Further rehearsal is to be carried out annually and in case of factory having hazardous
process rehearsal is to be carried out once in six months. To check and examine the
effectiveness, awareness and preparedness of the plan as well as services. The
emergency planning is not a substitute for good design, operating and maintenance
practices. Therefore, safe habits must always be followed to avoid an emergency.
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4.1 POSSIBLE HAZARDOUS SCENARIO
The possibilities which may lead to emergency, based on the hazardous chemicals stored,
handled & processed at the plant, have been explained.
Salient properties of hazardous chemicals are given and MSDS of salient hazardous
chemicals are given in Chapter-9.
4.2 PRE INCIDENT PLANNING
The specific details of Hazardous chemicals are prepared to respond to the emergency.
However, considering the various hazardous activities on production and storages, the
management has developed the preparedness and awareness amongst the staff,
contractors and visitors.
4.3 COMMAND & CONTROL

Flow Chart of Emergency Response during the emergency is given at Chapter-3, which
foresight the order of command, channel of information flow and action with gravity of
situation as required to deal with the emergency. The single organization structure has
been constituted and same shall be continued till the emergency is over. The Head of the
respective department shall take the initial charge as incident controller, and he will
coordinate with different departments including Safety Department to respond to the
situation. On arrival of Site Main Controller to the site, he gets status of situation from the
Incident Controller and Safety Head. After assessing the situation, he will declare the”
EMERGENCY” & he will act as Site Main Controller and put On Site Emergency Plan in
action.
4.4 ASSEMBLY POINT
The assembly points are marked at a conspicuous place, list given in section 3.3.
Individuals have to choose Assembly point well away from areas of risk and least affected
Page 31
by the downwind direction or they have to go at Assembly point as directed by IC/ Security/
Fire & Safety Department / Control Room
The nominated person for recording the names and departments of those reporting should
be posted there in advance by HR Department. He should have a means of
communication with the site main controller in case it is necessary to establish the
whereabouts of people and to receive further instructions concerning the deployment of
the evacuated personnel.
4.5 ECC DATA UPDATION
The following arrangements are available and details are given. But it shall be periodically
up-dated for preparedness of emergency purpose, during pre-emergency period.
i.M.S.D.S.:
M.S.D.S. for The Selected Hazardous materials, which are handled and stored at the site,
is given in Chapter-9.
ii.Weather Condition Data:

The Meteorological data which will be updated periodically and record will maintained
accordingly.
iii.Communication System:
Telephone Nos. with name of contact person etc. is given in Chapter 12.4.
iv.Emergency Control Centre:

The Equipped Central Control Room shall be in working order. The plant layout, maps,
drawings, storage details, M.S.D.S, emergency operations, manuals etc. is kept available.
List of essential telephone Nos. is also maintained up to date. The senior and expert
person shall be posted as in charge of the control room.
v.Fire Protection:
The details on Fire Protection system are given in Chapter-6.
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All fire – fighting equipments and machineries are periodically checked their conditions,
physical availability and workability. Necessary actions are taken for replacement and
maintenance, if required. Fire Water levels at reservoir checked daily.
vi.Personal Protective Equipment:

The details of Personal Protective Equipment are given in Chapter -6.
All personal protective equipment provided at different places are checked for their
condition & sound working. Maintenance and replacement is carried out, whenever
required. Sufficient stocks of required personal protective equipment are maintained.
Relations also maintained with the mutual aiders for their supply of Personal Protective
Equipment at the time of emergency.
vii.Safety Systems:
All safety devices, interlock systems, alarms and safety-guards are checked periodically.
The safety equipment are kept available in working condition. The safety motivation and
safety training is a continuous process and such type of trainings are arranged periodically.
viii.Spare Empty Vessel/Tank/Containers:

Extra storage space/vessel is kept available for emergency transfer of hazardous
chemicals.
The storage tank is kept empty but in working condition. Bund/dyke around the storage
tanks and isolation valves are checked and kept in working condition.
ix.The Medical Facilities:

The First Aid Boxes provided at the plant area are adequately filled with requisite
medicines and equipments. Arrangement is made that at least one trained person is
available during the working hours. The name and address with telephone No. of Doctors
is displayed in the Control Room along with General Hospital & Ambulance Van facilities.
x.Monitoring The Environment:

The constant monitoring of the environment is being carried out for detection of possible
damages or risky situations, and record in form-37 is maintained,
xi.Preventive Maintenance:
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A procedure for scheduled periodical preventative maintenance and inspection of the

plants, equipment, storage tanks, air compressors, D.G. Sets, Boiler etc. is laid down &
records are maintained.
Test, examination and certification are carried out within a reasonable period.
xii.Preserving The Records:

SMC along with HOD have to ensure that all records of the monitoring conditions, safety
systems, storage levels, process condition PERMITS log – books, registers etc. M.S.D.S.
onsite emergency plan, other required details pertaining to the emergency incident is
preserved.
xiii.Exercises/Mock Drill/Rehearsal:
The mock drill/ rehearsal/exercise are conducted annually and Factory having hazardous
process mock drill/ rehearsal shall be conducted once in six months as per statutory
requirement. Preparedness & awareness is created amongst the employees. Deficiencies
of the system during the mock drill are recorded and appropriate action is taken to improve
the effectiveness of the plan in terms of preparedness and response. Suggestions derived
from mock drill for improvement are included in next Mock Drill. Prior intimation with
reasonable time is given to the emergency services and public for proper response.
xiv.Liaison updation on continual basis:

Keep constant liaison with mutual aiders, fire services, police department, medical
services, statutory authorities, district administration, for pre emergency situation. Liaison
with local Crisis Group and District Crisis Group are maintained
xv.Disclosure to Public:
The public in the vicinity of the complex are educated on hazards existed in plant and
response action required during emergency period. Through pamphlets, leaflets,
organizing seminar or talk etc. Students from schools are trained in this respect, also. The
management has tried to cover larger areas by doing various efforts to educate the people.
xvi.Training:
Page 34
With the help of efficient plant supervisors & inspectors, education & training of the workers
are kept alive all the time to ensure good housekeeping, discipline. Safety slogans,
cautionary notices, operative instructions are displayed at conspicuous places. All the
people from the emergency services, organization are trained to respond to the
emergency.
CHAPTER-5: COMMUNICATION ARRANGEMENTS
After the Risk and their possible environmental impact and after making an organization
for the preparedness to control the emergency, the next step is to make ready the
communication system. It is a crucial factor in handling an emergency.
Under section 41-B of Factories Act, now the disclosure of information to the workers,
general public, local authority and the chief inspector are made compulsory. Such advance
communication is for the purpose of their emergency preparedness.
For the purpose of on-site plan, we should have quick and effective communication system
to make the emergency known
(a) Inside the factory.
(b) To key personnel outside normal working hours.
(c) To the outside emergency services and authorities and
(d) To neighboring factories and public in vicinity.
The communication system beginning with raising the alarm, declaring the major
emergency and procedure to make it known to others is explained below in brief.
5.1 RAISING THE ALARM
Any person who notices any incident of hazardous nature i.e. fire, Explosion, Spillage of
Toxic & Hazardous Chemicals, Toxic Gas leakage etc. he will first inform his superior and
co-worker.
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Details of alarms and sirens should be provided in the factory & different siren codes as
below.
Mode Type of sound of alarm/siren Duration of

sounding
Fire (On-site)
20 Seconds
On 10 sec, Off 10 sec (2 times in Fire)
Gas Release(On-site)
On 20 sec, Off 20 sec, (3 times in Gas 2 Minutes

leak)
Off Site
On 30 Sec, Off 30 Sec (2 times in 2 2 Minutes

minutes)
All clear
3 Minutes
Continuous
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5.1.1. WARNING ALARM AND SECURITY SYSTEM
Plant wise alarm points 1 Sound difference if any

Sr. Plant / Dept. / Type of the Its Period Type of Duration
Type of Type of sound of
No. Location alarm or of alarm or of
emergency alarm / siren
Name & location siren checking Siren sounding
Gas leakage
Siren Fire
1 Velling Velling for Continous for 3
Security Area electrically daily
sound 2 minutes minutes
operated Toxic release
Injury
Note: In case of electrical failure D.G.Set is available.
Page 37
5.1.2 SECURITY SYSTEM:
⮚ A premise is covered by Wall and Main gate is secured by guard for 24 hours.
⮚ All transport vehicles are checked at the gate for driver licenses, MSDS, Emergency
Information Panel, etc.
⮚ Security staff takes round throughout the factory for security of plant & others.
5.2 DECLARING THE MAJOR EMERGENCY
The declaration of major emergency puts many agencies on action and the running system
may be disturbed which may be very costly at times or the consequences may be serious,
therefore such declaration should not be decided on whims or immature judgment or
without proper thought.
5.3 TELEPHONE MESSAGES
After hearing the emergency alarm and emergency declaration or even while just receiving
the emergency message on phone, a telephone operator has to play an important role. He
should be precise, sharp, attentive and quick in receiving and noting the message and
then for immediate subsequent action of further communication.
A form is suggested for a telephone operator to receive and record the first emergency
call.
5.4 RUNNER
In case of failure of telecommunication system in areas where flammable vapours or
material is present, the runner will be helpful for communication.
5.5 COMMUNICATION OF EMERGENCY

There should be an effective system to communicate emergency.
a) Inside the factory i.e. to the workers including key personnel and essential workers,
on duty and inside during normal working hours.
b) To the key personnel and essential workers not on duty and outside during normal
working hours.
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c) To the outside emergency services and the government authorities and,

d) To the neighboring firms and the general public in the vicinity.
5.6 TO KEY PERSONNEL OUTSIDE NORMAL WORKING HOURS
Generally because of the planning suggested the key personnel and essential workers will
be available in all shifts or on short call. But due to some reason, if some are outside or
not on duty and if their help is required, their up-dated lists (Annexure-5) shall be kept and
(if located elsewhere) the communications centre from which the call will be made.
Names should be listed in order of priority. Communicators should be told to call in the
personnel in the order given, but not to waste time hanging on unduly for the call to be
answered. Instead, they should proceed through the list and return to those where the
initial call was unanswered. If the second call remains unanswered, they should try to
contact the nominated deputy.
On making contact, the communicator should give a short prearranged message to the
effect that a major emergency has been declared at the works. Those contacted should
not try to elicit further information at this stage, thereby delaying other calls. Liaison with
the police will help to establish means whereby personnel called in can be allowed to
proceed through any roadblocks set up as part of their traffic control arrangements.
5.7 TO THE OUTSIDE EMERGENCY SERVICES AND THE AUTHORITIES
Once the declaration is made, it is essential that the outside emergency services, if they
have not already been called in, are informed in the shortest possible time. Liaison at local
level will help to determine the best means of achieving this, for example, by direct line or
automatic alarm to the fire brigade or by any emergency system. Predetermined code
words to indicate the scale and type of the emergency may be useful.
In high risk works and where there is no full time works emergency team, it may be
advisable to provide for the outside emergency services to be informed on all occasions
when the emergency alarm is raised. Local discussion with the outside services will help
to decide, but it should be borne in mind that it is better for the emergency services to
Page 39
arrive to find a situation already under control than to find one out of hand due to delay in
call-in.
The emergency must be immediately communicated to the government control room and
other authorities such as fire brigade, police, district emergency authority, factory
inspectorate, hospital, etc.
The statutory information to above authorities must be supplied beforehand so that they
can be well prepared to operate their offsite emergency control (contingent) plan. As per
their advice or consultation on-site plan is modified and updated also.
5.8 TO NEIGHBOUR FIRMS AND THE GENERAL PUBLIC
A major emergency may affect areas outside the works. The surrounding public will be
alerted with PA system. The police will undertake any necessary action to safeguard
members of the public. In the case of other nearby industrial concerns, consideration
should be given to the need for a direct notification to them of the major emergency. This
can serve a dual purpose in that it will enable them to take prompt action to protect their
own employees and to take whatever measures may be possible to prevent further
escalation of the emergency due to effects on their own installations. At the same time,
they may be able to provide assistance as part of a prearranged mutual aid plan.
The statutory information to the general public must be supplied before hand to them for
their emergency preparedness. Such information u/s 41-B of the factories act is as under.
1) Name of the factory and address where situated.
2) Identification by name and position of the person giving the information.
3) Confirmation that the factory has approval from the factories inspectorate and
pollution control board.
4) An explanation in the simple terms of the hazardous process (s) carried on in the
premises.
5) The common names of the hazardous substance used which could give rise to an
accident likely to affect them, with an indication of their principal harmful
characteristics.
6) Brief description of the measures to be taken to minimize the risk of such an
accident in compliance with its legal obligations under relevant safety statues
7) Salient features of the approved disaster control measure adopted in the factory.
Page 40
8) Details of the factor’s emergency warning system for the general public.
9) General advice on the action members of the public should take on hearing the
warning.
10) Brief description of arrangements in the factory, including liaison with the
emergency services to deal with foreseeable accidents of such nature and to
minimize their effects.
11) Details of where further information can be obtained.
Page 41
CHAPTER- 6: FIRE FIGHTING AND OTHER ARRANGEMENTS FOR

EMERGENCY
6.1 AVAILABILITY OF FIRE FIGHTING FACILITIES:
Fire Water
Existing 01 Proposed 01 Total Quantity 148 Kl + (Proposed 150 Kl)

Reservoir Reservoir
Other Hydran Fire Pumps, Hose No. of Fire Panel System Alternative Extinguishe
Sources & t Points Type & Reels Sprinklers Power rs
Capacity Capacity arrangemen
t
Detector MCP PA
Process Yes 01 No. Fire main Yes Provided at Yes Yes Provided D.G. Set Yes
Water pump 2850 LPM
Storage all floors &
01 No. Diesel offices
MIDC Fire pump 2850 LPM
Service
01 No. Sprinkler
pump 2850 LPM
02 Nos.Jockey
Pump 180 LPM
Page 42
CHAPTER- 7: MUTUAL AID ARRANGEMENTS

7.1 MUTUAL AID
Since combating major emergencies might be beyond the capability of individual unit, it is
essential to have mutual aid agreements with neighboring industries. Consideration shall
be given to the following while preparing mutual aid arrangements:
(a) Written mutual aid arrangements are to be worked out to facilitate additional help
in the event of Level-2 emergencies by way of rendering manpower, medical aid or
fire fighting equipment, etc.
(b) The mutual aid arrangement shall be such that the incident controller of the
affected installation shall be supported by neighboring industries on call basis for the
support services materials and equipments already agreed. Further, all such services
deputed by member industry shall work under the command of the INCIDENT
CONTROLLER of the affected installation.
(c) Mutual aid associations shall conduct regular meetings, develop written plans and
test the effectiveness of their plans by holding drills. Drills are essential to establish a
pattern for operation, detect weaknesses in communications, transportation and training.
Periodic drills also develop experience in handling problems and build confidence in the
organization.
(d) To make the emergency plan a success, the following exchange of information
amongst the member organizations of mutual aid association is considered essential:-
i. The types of hazards in each installation and fire fighting measures.

ii. List of all the installations or entities falling along the routes of transport
vehicles carrying petroleum or petroleum products.
Page 43
iii. The type of equipment that would be deployed and procedure for making
the replenishment.
iv. Written procedures which spell out the communications system for help
and response. This is also required to get acquainted with the operation of
different firefighting equipment available at mutual aid members and
compatibility for connecting at users place.
v. Familiarization of topography and drills for access and exit details carried
out by mutual aid members.
Note: Incidents involving road transport vehicles carrying petroleum products shall be
attended by the nearest installation on request of civil authorities even in the absence of
mutual aid agreement with the consignor.
Page 44
7.1.1 MUTUAL AID ARRANGEMENTS OF FIRST- AID AND HOSPITAL SERVICES

AVAILABLE
Hospitals available nearby Telephone No. Approx distance
Name of the Hospital
Reliance Hospital, Kopar Khairane 022 3969 3969 1.2 Km
Sai Snehdeep Hospital, Kopar Khairane 097697 14066 3.3 Km
7.1.2 MUTUAL AID ARRANGEMENTS OF FIRE & TOXICITY CONTROL

ARRANGEMENTS
Sr. Fire Station With Designated Contact Persons

Type And Numbers Of Fire Tenders,
Address And Phone With Address (O, R) And
No. (Water, Foam, Mist Tenders)
Number Phone:- Numbers (O, R, M)
Fire Station Khairane 022 2778 0207

1 Water and Foam
MIDC
Page 45
7.1.3 MUTUAL AID WITH NEARBY ORGANISATIONS
Contact Person
Name & Address of the Factories
Name Phone No.
TTC-MIDC Association --- 022 2768 0211
Page 46
CHAPTER- 8: INFORMATION ON THE PRELIMINARY HAZARD

ANALYSIS
The Preliminary Hazard Analysis (PHA) consists in identifying, at the system level, which
redundant events can lead to dangerous situations for people. These events are then
classified by assigning a safety level.
This analysis is Identification, analysis, assessment of hazards and risk provide vital
information to risk management. Objective of this plan is to assess the risk and to provide
guidelines for facing and controlling the emergency.
This Chapter contains the information of possible accidents, hazards and Safety relevant
components.
8.1 TYPES OF ACCIDENT
a) Fire & Explosion.

b) Spillage of Acid & Alkali.
c) Collapse of Building, structure etc.
d) Toxic gas Dispersion.
8.2 SYSTEM ELEMENTS OR EVENT THAT CAN LEAD A MAJOR ACCIDENT
a) Leakage due to valve failure.

b) Gasket Failure, Pipeline punctured.
c) Failure of manual / automatic control system.
d) Inadequate design against internal pressure, external forces, corrosion and
temperature.
e) Overflow of storage tank.
f) Bomb threat, Terrorist attack, natural disaster, rain, flood, earthquake, storm &
cyclone.
g) Failure of manual / automatic control system.
h) Wrong operation of valve, over flowing of liquid from tank may result into fire or
mishaps.
Page 47
Page 48
8.3 HAZARDS
MAJOR HAZARDS IN STORAGE AREAS
a) Hot work.
b) Failure of storage tank.
c) Lightning.
d) Overflow of the storage tank.
e) Vacuum Sucking.
f) Pressurization of Storage Tank.
POTENTIAL AREA OF TOXIC HAZARD

a) Chlorine: Process reactor area.
b) Chlorine: chlorine Cylinder storage area.
c) Chlorine: pipe line.
8.4 SAFETY RELEVANT COMPONENTS
a) Necessary licenses from explosive department obtained.

b) SCBA (Self Contained Breathing Apparatus).
c) Personal Protective equipment.
d) Fire Fighting Extinguishers.
e) Dyke Provision.
f) Interlock System.
g) Mock drill of emergency preparedness plan.
h) Gas Detection System.
i) Water Sprinkler System.
j) Fire Hydrant Network.
k) Safety shower.
l) Scrubbers.
8.5 LOCATION OF DANGEROUS SUBSTANCES
● Storage tank.
● Gas Cylinder storage area.
Page 49
Page 50
CHAPTER- 9: DESCRIPTION OF HAZARDOUS CHEMICALS AT PLANT

SITE
9.1 RAW MATERIALS STORAGE :
RAW STORED TYPES OF CONTROL MEASURES

MATERIAL IN POSSIBLE PROVIDED
HAZARDS
(FIRE,
EXPLOSION,
TOXIC)
1. Provided all personal protective
H2SO4 98% Carboy Reactive
equipments to the workers and
SODA ASH Bag - maintained in good working
conditions.
Pt.1% + Cu 0.1% Bag - 2. Water safety shower and eye
washer are provided at a suitable
Nitrogen Cylinder m3 Explosion place.
3. Fire extinguishers are provided
Hydrogen Cylinder m3 Explosion 4. Acid, Alkali cautionary notice has
been displayed at places.
Caustic Flakes Bag -
5. Flame proof fitting are provided.
6. Skilled supervision is provided.
HCL 30% Drum Reactive
3% PT (Real) Bag -
Di methyl Drum Fire & Explosion

Acetamide (DMAc)
4,4 DNDPE Bag -
PD/C 2% (As is) Bag -
Page 51
HDPE Bags with -

liner
Aluminium Sulphate Bag -

(Ferric Alum )
PD/C 1% (R) Bag -
Mono Chloro Drum Fire

benzene ( MCB )
2,4 DNA ( Di Nitro Bag -

Aniline )
4-Nitro Benzoyl Bag/ Fire

Chloride Drum
Liquor Ammonia Drum Fire

(25%)
Activated carbon Bag -
PD/C 5% (R) Bag/ -

Drum
N-Methyl Drum Fire

pyrrolidone (NMP)
Nitric acid 98% Glass Reactive

Bottles
Para Toluidine Drum Fire
Ferric Chloride
Page 52
Para Phenylene Di
Amine (PPDA)
2-Fluoro 3-Chloro
Nitro-Benzene (2,3
FCNB)
Dilute Sulf Acid 76%
Ibc Tank
PDCB
Sulfamic Acid
Page 53
2.0 Detail MSDS are available at:
1. R&D Manager / office.

2. Pilot Plant
3. Safety Department.
4. Laboratory / R&D.
Page 54
9.2 OTHER HAZARDS & CONTROLS
Name of the Its source & reasons Its effects on Place of Control measures provided
possible hazard or persons, effect
emergency property &
environment
Lightening Natural Lightening Fire Entire Lightening arrester
Factory
Flood Heavy Rain Property -do- -

damage
Drowning
Earthquake / Earthquake Property -do- -
Tsunami damage
Riot/ Subotage/ Riot/ Subotage/ Property loss/ -do- Manned with Security staff
Agitation Agitation damage
Noise D.G. Set Health hazards Utility Ear protectors
Tide/ Typhoon / Nearby Seashore Property Entire Due care while design
Cyclone/Tsunami damage factory,
Jetty
Structural collapse Explosion/ Implosion/ Property Ammonia Periodic inspection and
Tide/ Typhoon/ damage tank maintenance for structures
Cyclone/ Flood etc. stability
Emergency at Gas exposure Depends on the Entire Depends upon the situation
Neighbouring type of factory
Industries emergency
Page 55
CHAPTER 10. Preliminary Hazard Analysis:
10.1 Fire in plant :-
● Try to extinguish the fire by using fire extinguishers located at designated places if
possible and safe, at the same time alert other surrounding people by shouting or “fire
fire”
● Assess the type and intensity of the fire and inform site controller accordingly.
● Carry out the electrical isolation of particular floor / area including solvent transfer
pump ( if required )
● Pneumatic and manual valve should be closed as required.
● Unroll fire hose reel and try to extinguish fire.
● Simultaneously connect fire hose to the nearest fire hydrant points and start
extinguishing the fire.
● In case of major fire sprinkler system will be started if not started.
● In case of electrical failure diesel pump will start.
● Once Fire Brigade arrives on the spot handover firefighting operation to them and
stand nearby for assistance.
10.2 Fire in Boiler area.

● Try to extinguish the fire by using fire extinguishers located at designated places if
possible and safe, at the same time alert other surrounding people by shouting or “fire
fire”
● Evacuate the area.
● Stop the operation of the boiler and carry out the electrical isolation.
● Barricade the area and eliminate the source of ignition.
● Pneumatic and manual valve should be closed.
● Connect fire hose to the nearest fire hydrant points and start to extinguish the fire.
● Once Fire Brigade arrives on the spot handover firefighting operation to them and
Page 56
10.3 EXPLOSION
Plant area (Reactor, Intermediate tanks)
● Immediately sound the alarm and evacuate the area.

● Report this to the person in charge of Emergency response.
● All the people report to assembly point.
● Stop all the operation and carry out the electrical isolation.
● Eliminate the source of ignition.
● Call the fire brigade and ambulance.
● Head count and report if anyone is missing.
● Rescue team should wear the appropriate PPE and rescue the people and get the
medical assistance.
● Try to extinguish the fire by using fire hydrant system.
● Once Fire Bridge arrives on the spot. Handover firefighting operation to them and
Boiler Area
● Immediately Sound the alarm and evacuate the area.

● Rescue team should wear the appropriate PPF and rescue the people and get the
medical assistance.
● Try to extinguish the fire by using fire hydrant system / fire foam monitor.
Page 57
Page 58
Drums Explosion
● Try to extinguish the fire by using fire extinguishers located at designated places, at
the same time he should alert other surrounding people by shouting or “fire fire”
● Immediately evacuate the area.
● If major, Sound the alarm.
medical assistance.
● Try to extinguish the fire by using fire hydrant system .
Electrical Installation (Transformer)
● Immediately Sound the alarm and evacuate the area.

● Eliminate the source of ignition.(If any)
● Start the Diesel pump and try to extinguish the fire.
medical assistance.
Page 59
CHAPTER- 11: EMERGENCY DUE TO NATURAL CALAMITIES
11.1 TYPES OF NATURAL CALAMITIES & ITS ACTION PLAN:
1) Earthquake:
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Whereas, seismic experts have opined that the Indian land mass is being constantly compressed
between the sea and the Himalayas and thus the developed stresses are being released in the form
of earthquakes in the least expected areas.
DURING EARTHQUAKE, if indoors:

● Take cover under a piece of heavy furniture or against an inside wall and hold on.
● Stay inside.
● The most dangerous thing to do during the shaking of an earthquake is to try to
leave the building because objects can fall on you.
DURING EARTHQUAKE, If outdoors:
● Move into the open, away from buildings, street lights, and utility wires.
● Once in the open, stay there until the shaking stops.
DURING EARTHQUAKE, If in a moving vehicle:

● Stop quickly and stay in the vehicle.
● Move to a clear area away from buildings, trees, overpasses, or utility wires.
● Once the shaking has stopped, proceed with caution. Avoid bridges or ramps that
might have been damaged by the quake.
AFTER EARTHQUAKE
● Be prepared for aftershocks. Although smaller than the main shock, aftershocks
cause additional damage and may bring weakened structures down. Aftershocks
can occur in the first hours, days, weeks, or even months after the quake.
● Help injured or trapped persons.
● Give first aid where appropriate.
● Do not move seriously injured persons unless they are in immediate danger of
further injury.
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● Call for help.

● Listen to a battery-operated radio or television for the latest emergency
information.
● Remember to help your neighbors who may require special assistance-infants, the
elderly, and people with disabilities.
● Stay out of damaged buildings.
● Return home only when authorities say it is safe.
● Use the telephone only for emergency calls.
● Clean up spilled chemicals or other flammable liquids immediately. Leave the area
if you smell gas or fumes.
2) Lighting & Thunderstorm:
BEFORE
● Thunderstorm is invariably accompanied by lightning A single stroke of lightning

has 125, 00, 000 volts of electricity. That’s enough power to light a 100-watt light
bulb for more than 3 months, or enough to seriously hurt or to skill someone. Know
what steps to take in the event of an oncoming thunderstorm & lightning. Lightning
is something you should not be careless about, so seek a safe shelter immediately!
Be warned, lightning can and does strike just about any object in its path. When
you see lightning, follow these safety rules.
INDOORS
● Stay or go indoors! If you hear thunder, don’t go outside unless absolutely

necessary. Stand clear from windows, doors, and electrical appliances.
● Stay away from anything that could conduct electricity. This includes electric, lines,
Electric Instruments, wires etc and phones. Unplug appliances well before a storm
strikes .
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● Don’t use any plug-in electrical instruments. If lightning strikes your building they
can conduct the charge to you.
● Don’t use the telephone during the storm. Lightning may strike telephone lines
outside. Use the telephone only for emergencies quickly. Avoid contact with piping
including sinks, baths and faucets.
OUTDOORS
● When outdoors, seek shelter from lightning. Buildings are best for shelter, but if no
buildings are available, you can find protection in a cave, ditch, or a campus. Trees
are not good cover. Tall trees attract lightning. Never use a tree as a shelter.
● Stay in your vehicle if you are travelling, vehicles gives you excellent lightning
protection. Get in a hard topped car.
● If you can’t find shelter avoid the tallest object in the area. If only isolated trees are
nearly, your best protection is to crouch in the open, keeping twice as far away
from isolated trees are high. Avoid areas that are higher than the surrounding
landscape.
● Don’t use metal object outside. Keep away from metal objects including bikes,
electric or telephone poles, fencing, machinery etc.
● Get out of the water. Immediately get out and away from pools, lakes, and other
bodies of water.
● When you feel the electrical charge – if your hair stands on end or your skin tingles-
lightning may be about to strike near you. Immediately crouch down and cover
your ears. Do not lie down or place your hands on the ground.
● Victims of lightning shock are administered CPM (Cardiopulmonary resuscitation)
i.e. artificial respiration, if necessary. Seek medical aid.
3) Heavy Rain:
● Stay out of the basement.

● Stop all jobs outside.
● Heavy rain many times accompanies high-speed wind. Stop all work at height.
● Disconnected power supply to all electrical Machines in open yards.
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● Cover all JBs\DBs were chances of water coming to it are there.

● Keep Gumboot, Raincoat and umbrellas ready.
● Keep all dewatering pumps ready in working order.
● Move valuable objects upstairs only if safe to do so, without straining yourself.
● Keep yourself indoors and away from rivers and creeks.
● Stay away from low/lying areas.
● Avoid walking through a waterlogged area on foot as you can get swept away
easily.
● Assemble everyone inside shelters or buildings.
● Close windows and blinds.
● Evacuate rooms that might bear the full force of the wind
● Avoid enclosures that have long roof spans.
● Keep the office radio tuned to a local station for current advisory information
4) Cyclone
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⮚ Looking to the moderate risk of cyclone, roof sheet / louvers sheet/ etc
shall be kept secured and shall be checked regularly. Any loose
material/ sheet etc shall not be kept on the terrace, height.
● Keep listening to the radio for updates and advice.
● Disconnect appliances.
● Stay inside well clear of windows, sheltering in the strongest part of the house
(internal hallway, bathroom or cellar).
● Keep your emergency kit with you.
● If the building begins to break up, protect yourself with a rug, mattress or blanket
and shelter under a bench or table.
● Do not assume that the eye of the cyclone means the danger has passed - wait
for the 'all clear'
● Stay in your vehicle if caught on the road, with the car handbrake on and parked
well clear of trees, powerlines and possible flooding.
● Never drive, ride or walk in floodwaters.
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CHAPTER- 12: INTEGRATION OF ON-SITE EMERGENCY PLAN WITH

DISTRICT OFF-SITE PLAN
12.1 PURPOSE OF THE OFF SITE EMERGENCY PLAN:
The main object of the off site plan is to create preparedness and to control various types
of emergency/disaster.
The main purposes of the off-site emergency plan are:
1. To provide the local/district authorities, police, fire brigade, doctors, surrounding

industries and the public, the information of risk and environmental impact
assessment and to appraise them of the consequences and the
protection/prevention measures and control plan and to seek their help to
communicate with the public in case of a major emergency. This information from
every industry enables the District Authorities to educate the public that what can
go wrong, the measures taken and to train them of their individual role in case of
emergency.
2. To assist the local/District Authorities for preparing the off-site emergency

(contingency) plan for the district or particular area to organize rehearsals from
time to time and initiate corrective actions based on the lessons learnt. This will
include:
a) To prepare a site plan identifying industries, hazardous points, control

points, assembly points, hospitals, dispensaries, fire station, police station,
railway station, bus station, transport points, roads and all other requisite
details.
b) To verify the information given by the industries to comprehend dangers
and to arrange for adequate personal protective, fire fighting and
emergency equipment.
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c) To establish command structure and to identify the respective roles of the

senior personnel of various service groups, toxicity control and
decontamination squads and various authorities of water, power, gas,
health, labour, environment, revenue, explosive, pollution control, press,
post, telephone, wireless, railway, transport and social services etc.
Necessary representatives of employers and employees shall also be
incorporated. Various organizations, their duties, equipment,
implementation procedure and action on-site and off-site, warning system,
communication system, coordination system, control centers, key
personnel shall be prescribed.
d) Plan to carry out training programmers in safety, health and environmental
protection for the concerned parties. Necessary publication will also be
useful.
e) To maintain full liaison between all agencies to this plan, industries,
emergency services etc.
f) To plan for the antidotes, remedial medicines and equipment in the
hospitals and to carry out research for them for latest and effective
measures, sufficient stock and mutual aid scheme will be useful.
g) To provide for continuous monitoring system for essential parameters of
pollution to judge malfunctioning at the initial stages and warning system at
appropriate places. Meteorological information regarding prevailing
weather conditions, wind velocity and direction, rain and flood data for such
data-collection.
h) To appoint a record keeper, historian and staff to collect information on the
causes of disaster and to maintain a record thereof and also of the plan-
proceedings.
i) To carry out mock drill and rehearsal of this plan to ensure its efficacy, test
and response, interaction and coordination of operators, various service
organizations, evaluate the effectiveness and adequacy of the equipment
and to gain experience and confidence to implement the plan. The finalized
Disaster Plan shall be given to all concerned for implementation and
rehearsal.
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j) To operate this plan at the time of off-site emergency by the Chairman, i.e.,
the District Collector. Such operation shall include:
i. To contain, limit, localize and minimize the loss and damage to

persons, property and the environment arising from the accident on
road or industry, transport, storage or otherwise. To plan to decrease
the potential of the disaster.
ii. To prevent the spread and re-happening of the disaster.
iii. To inform people and surrounding about emergency and disaster if
it is likely to adversely affect them. Machinery will be established for
this purpose to guide the people in a proper way.
iv. To plan for rescue and recuperation of casualties and injuries. To
plan for relief and rehabilitation.
v. To plan for evacuation, safe assembly points and transportation
required.
vi. To plan for prevention for harms, total loss and recurrence of
disaster. It will be ensured that absolute safety and security is
achieved within the shortest possible time.
⮚ The diagram below shows the relation of off-site plan within the scheme
of disaster management plans.
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12.2 SCHEMATIC DIAGRAM SHOWING ACTION FROM INCIDENT PLACE TO STATE

LEVEL GROUP
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12.3 ROLES AND RESPONSIBILITIES OF STAKEHOLDERS INCLUDING EXTERNAL

AGENCIES
The general responsibilities of the various authorities and agencies involved in mitigation
of off-site emergency are listed below. In addition, the authorities and agencies will perform
all such tasks as per the demands of an emergency situation at hand.
Duties of Site Main Controller

During the Off Site Emergency, Unit’s Site Main Controller becomes coordinator & Liaison
person and his duties are as follows:
● He has to extend liaison, coordination and facility to the Chairman of local crisis
group or Chairman of district crisis group.
● He has to explain about disaster, his efforts and what type of help is needed in
brief to Chairman of Local Crisis group (Govt. Authority) and Central Control Room.
● He has to communicate about available resources, fatality/injury to his own
employees and probable affected surrounding area with maximum credible
scenario.
● He has to keep ready with maps, layout of unit, records, documents, On Site
Emergency Plan, M.S.D.S., Details of Process Hazards, Safe Handling procedure
on specific hazardous chemicals, etc.
● He has to advise for special medical treatment and availability of antidotes.
● He has to divert Communication system for Offsite emergency.
● He has to divert all available resources for Offsite emergency.
● He has to provide aid and assistance for Off Site Emergency.
● Shutdown plant safely, if hazards is not involved.
● He has to reorganize the work of Key personal & essential worker.
● Arrangement of food, water, rest, etc. for the person engaged in the duty.
● Arrangement of disposal of contaminated water, effluent, solid waste, etc.
Duties of Incident Controller

● He has to show the actual incident place to offsite action group.
● He has to provide proper information to all incoming off site action group.
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● He has to also explain safe route for offsite team members, fire crew members,
etc.
● He has to describe the available resources, other hazardous material near
disaster, available PPE, Neutralizing Media, etc.
● He has to show safe & proper parking arrangement for offsite action group
members.
District emergency Authority (DEA – District Collector)

● Take overall responsibility for combating the Off-site emergency
● Ensure the Police and Fire personnel combat the emergency
● Arrange, if necessary, for warning and evacuating the public, through the
Department of Police
● Communicate with media to disseminate vital information to public
● Arrange for dispensing vital information to the public using arrangements like
mass-sms, public announcement using pre-recorded tapes.
● Direct the team of Doctors headed by the Medical Officer.
● Direct the local chief of State Transport Corporation to arrange for transport of
victims and evacuation of people trapped within the hazard zone, if necessary.
● Direct the Electricity Board officials to give uninterrupted power supply.
● Direct the official in-charge to provide uninterrupted water supply as required.
● If evacuation of population is necessary to direct the Revenue officer and the
Supply officer to provide safe shelters, food and other life sustaining requirements
for the evacuees, if required.
● Coordinate with the media.
● Arrange for, release and provide the necessary funds at various stages of disaster
mitigation.
● Direct railways to stop train, if required.
Police
Communicate and coordinate with --
● MAH unit
● DEA (District Emergency Agency)
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● Fire Services
● Transport authorities
● Medical Department
● Media
● Civil Defense and Home Guards
● Local Army establishment as required
● Warn and advice the people in the affected area
● Regulate and divert traffic
● Arrange for evacuation
● Maintain law and order in the area
● Ensure protection of life and property of evacuees
● Deal sternly with people exploiting opportunism in wake of a disaster.
Fire Service Department

● Perform fire-fighting operations by deploying men and appliances
● Perform rescue operations in the affected area.
● Communicate and coordinate with Police,Medical Department of necessary
information
● Keep knowledge on appropriate response to different chemical emergency
scenarios
● Keep adequate stock and resource information on necessary means, material,
appliances required to deal with particular emergency situations with updated
details of suppliers and stockist
Medical Department
● Arrange for preparing casualties to be sent to government/private hospitals
● Set up temporary medical camp and ensure medical facilities at affected location
and neighborhood
● Keep knowledge on appropriate response to different cases of toxic consumption
and injuries
● Set up temporary mortuary, identification of dead bodies and post-mortem
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Factory Inspectorate Department

● Provide necessary direction to MAH unit and assistance to DEA, Fire Department,
Medical Department among others
● Seek help from and involve assistance of Technical Experts of relevant and
appropriate expertise and specialization
● Initiate, facilitate and provide for investigation into the accident
Occupier of MAH Unit

● Possess up-to-date copy of Off-site Emergency Plan
● Communicate promptly, any foreseeable disaster, to the DEA, Police, Fire Service
and Inspector of Factories in-charge of the District
● Communicate changes within the factory that may require inclusion or suitable
modification in the off-site plan to the DEA (Maintenance Officer) of the Plan
Technical Experts
● Promptly respond to provide the necessary technical advice to MAH unit, DEA,
Factory Inspectors, Fire Department, Medical Department among others.
● Provide on-phone help after properly understanding and assessing the situation.
● Make visit to the site in coordination with DEA, Factory Inspector(s) to provide for
appropriate technical assistance.
Mutual AID Groups

To quickly mobilize the resources required to emergency mitigation at the site or wherever
required.
Pollution Control Board

● Project likely areas to be polluted.
● Carry out pollution assessment at suspected locations including soil, river and air
assessment
● Ensure controlling of long-term pollution damage
● Identify unidentified substances, chemical releases, if any
● Transport Fleet Owners Including State Transport
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● Act on the direction of DEA or Police

● Ascertain the extent of transport required with pick-points, routes and destinations
to transport people
● Promptly arrange for the dispatch of vehicles with sufficient fuel for evacuation
purposes
● Arrange vehicles to transport water and other provision to camps set up
Media
● Disseminate vital information to the public on direction of DEA, Police and other
Authorities
● Act responsibly in disseminating vital information and dispel rumours, if any
Railways
● Act as per the direction of DEA to stop incoming trains, if required
● Arrange for evacuation, if required
Transporters of Hazardous Chemical

● Possess up-to-date copy of Off-site Emergency Plan
● Communicate promptly, any foreseeable disaster during transportation to the DEA,
Police, Fire Service and Inspector of Factories in-charge of the District
● Communicate new assignments, newly added routes or other changes that may
require inclusion or suitable modification in the off-site plan to the DEA
(Maintenance Officer) of the Plan
Electricity Board
● Arrange for uninterrupted power supply to the plant, as required
● Arrange for lighting; at temporary medical camps etc
● Arrange for switching off power supply on request from District Authorities
● Take care of electrical equipment within the damaged zone
Telecommunication Department
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● Ensure working of communication lines to enable effective communication

between various responder agencies
Civil Defense
● Coordinate with Police authorities
● Extend help in evacuation
● Arrange for round the clock security arrangements in the affected and evacuation
areas
● Safeguard the properties and belongings of evacuees
National Disaster Response Force

● Carry out tasks for disaster mitigation as required
Local Government Bodies

● Mobilize necessary resources in emergency mitigation
● Provide for community halls, town halls for evacuees
Public Works Department

● Ensure adequate water supply for firefighting
● Arrange for drinking water for evacuated persons at rallying posts, parking yards
and evacuation centers. Arrange water for cattle.
Water Supply Board

● Arrange for supply of water to evacuees and all others involved in emergency
control operations
Civil Supplies Department

● Arrangement to provide food and clothing as necessary, to the evacuees and all
others involved in emergency controlling operations
Regional Transport Authority
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● To investigate into the cause of road accident involving hazardous goods carrier
and take necessary action
Note: If any incident happens in plant premises responsible person has to rush to the site
immediately
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12.4 IMPORTANT EXTERNAL TELEPHONES NUMBERS
Sr. Phone Number

Name
No. Office Residence
A. EMERGENCY RESPONSE CENTRE
1 Police Control Room, Navi Mumbai 022 2757 4928 -
2 MIDC Fire 022 2778 0207 -
3 MPCB. CBD Belapur 022 2757 2739 -
4 RIL Hospital 022 3969 3969 -
5 DISH, Navi Mumbai 022 2757857 -
B. COLLECTORATE
1 Collector Office, Thane 022 25344041
C. POLICE DEPARTMENT
1 Commissioner of Police 022 27561099 022-2757 4929
2 Police Station, Khairane MIDC 022 27550777
D. GOVERNMENT DEPARTMENT (STATE & CENTRAL) & OTHERS
1 DISH Office, Bandra 022

26572504/ 09 / 22
2 Jt. Director, DISH, Navi Mumbai 022 2757857
3 MIDC Fire, Rabale 022 2769 8101
4 MIDC Fire, Dombivli 0251 2470357 -
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12.5 RECOVERY, RECONSTRUCTION AND REHABILITATION
The recovery and reconstruction phase of disaster management involves disaster relief:
immediate shelter, life support, and human needs to persons affected by, or responding
to, a disaster; the broader disaster recovery; the coordinated process of supporting
affected communities in the reconstruction of the physical infrastructure, restoration of the
economy and of the environment, and support for the emotional, social, and physical well
being of those affected
12.5.1 FUNCTIONS OF RECOVERY
For the purpose of effective coordination, aspects of recovery are conceptually grouped
into four functions. It is important to acknowledge that the four functions of recovery
overlap and recovery arrangements must reflect the inter-relationship between each of
these functions.
1. INFRASTRUCTURE
Infrastructure, or built environment, recovery includes repair and reconstruction of
residential and public buildings, commercial, industrial and rural buildings and structures,
government structures, utility structures, systems and services (transport, water, sewage,
energy, communications), and other essential services.
2. HUMAN-SOCIAL
Human-social recovery includes personal support and information, physical health and
emotional, psychological, spiritual, cultural and social well-being, public safety and
education, temporary accommodation, and financial assistance to meet immediate
individual needs and uninsured household loss and damage.
3. ECONOMIC AND LIVELIHOOD

Economic recovery includes renewal and growth of the micro economy (within the affected
area) and the macro economy (overall economic activity of the state). Economic recovery
includes individual and household entities (e.g. employment, income, insurance claims),
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private and government business enterprises and industry. It includes assets, production
and flow of goods and services. It includes capacity for the export of goods and services
from the affected region, and securing confidence of overseas markets.
4. ENVIRONMENT
Environment, or natural environment, recovery includes restoration and regeneration of
biodiversity (species and plants) and ecosystems, natural resources, environmental
infrastructure, amenity/ aesthetics (e.g. scenic lookouts), culturally significant sites and
heritage structures. It includes management of environmental health, waste,
contamination and pollution and hazardous materials.
12.5.2 TRANSITION FROM RESPONSE TO RECOVERY
The after-stage of response is defined as the period when there is no further requirement
for the coordination of response activities. As recovery activities being within the response
phase, it also signals the transition from response to recovery mode. In this transition the
emergency is declared over and the IRT hands over the planning and operations to the
relief commissioner or others as appointed by the chief secretary. Careful planning and
handover is essential with proper documentation for a successful transition. The major
steps taken during transition are as follows:
1. Preliminary Damage Assessment: State should deploy multidisciplinary team

to determine the extent of damage to communities.
2. Aid and Assistance: Identification of the type of public or individual assistance
necessary in an emergency declaration. These can be housing, grants, low-
interest loans, relocation, unemployment assistance, food commodities, or
legal services. Also includes assistance for community such as debris
removal, emergency protective measures, roads and bridges, drinking water,
buildings and equipment, and other utilities.
3. Mobilization of essential resources: Coordinate and ensure mobilization of
essential resources to a temporary location of emergency mass care where
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impacted survivors of disasters go for limited services and information within

24- 96 hours following the disaster.
4. Disaster Recovery Centres: Such temporary locations could be termed as
Disaster Recovery centre. Responsibility can be shared by the affected
district, state and central authorities.
5. Community Groups: Community groups should be deployed in the affected
community areas to disseminate information. These will identify and report
local unmet human needs and assist survivors.
6. Expenditure: Estimation of cost to be incurred by the agencies responsible
for relief and recovery for the reimbursement.
12.5.3 COUNSELLING AND REHABILITATION OF VICTIMS

The psychological impact of a chemical disaster manifested as psychosocial trauma
including psychological reactions, post-traumatic stress disorder, and other psychological
ailments in displaced disaster victims needs to be addressed. Counseling by psychologists
and psychiatrists for those suffering from mental trauma is an essential element of medical
rehabilitation.
12.5.4 IMMEDIATE FINANCIAL RELIEF TO VICTIMS
Under the Public Liability Insurance Act, 1991, MOEF has published the list of chemicals
and threshold qualities beyond which the occupier or owner must take third-party PLI for
providing relief to accident victims due to a chemical accident as per the direction of the
collector. The Act also provides for an Environment Relief Fund (ERF) and enables
payment of relief over and above the insured amount. The occupier or owner should pay
an amount equal to the PLI premium to the ERF and deposit the same with the insurer. At
state level MPCB is responsible to ensure compliance with PLI Act and at district level the
collector and regional officer of MPCB are responsible. This act provides for immediate
access to relief funds so that the compliance with Act should be verified and strengthened.
We have already recommended that the maximum liability under the Act (INR five cores)
should be substantially enhanced.
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12.5.5 RESTORATION AND REGENERATION OF ECOSYSTEM
The potential for chemical accidents to cause severe environmental damage has been
realized on a number of occasions such as at Seveso, Bhopal, Mexico City (LPG disaster),
Chernobyl, and Alaska (Exxon Valdez) amongst others. For the remediation of the affected
environment, it is essential to assess the environmental impacts, which include identifying
of the chemical released, determining the quantitative and qualitative nature of impact,
and ascertaining the components of the environment most at risk from chemical accidents.
This assessment is dependent on certain factors such as the chemicals involved, pollutant
concentrations in the environment, environment media polluted by the accident,
topography, assessing the impact, the government can choose the appropriate recovery
strategy.
RECONSTRUCTION OF DAMAGED STRUCTURES AND SERVICES

Major and catastrophic fires and explosions can result in significant damage to structures
although less in extent compared to earthquakes or tsunamis. Reconstruction offers us a
chance to build back better and safer. Reconstruction and restoration of infrastructure shall
be achieved at the earliest as per the following guiding principles laid out in the national
policy on disaster management.
1. Building back offers opportunity to build better and safer so that consideration
should be given in planning to open spaces, water and sanitation
infrastructure, health care facilities, education infrastructure, roads and safety
from disasters.
2. Reconstruction plans should be a participatory process involving the
government, affected community, NGOs and the corporate sector. After the
planning process is over, owner driven construction is a preferred option but
as per the guidelines and specifications in the planning.
3. Essential services and intermediate shelters/ camps should be established in
the shortest possible time. The restoration of normalcy and day-to-day
functioning is an important factor for consideration. For permanent
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reconstruction, the relocation option should be considered in case the

affected community was in the highly vulnerable zone illegally (e.g. squatters
or developments within buffer zone around a company). In case of large
chemical facility, the community may be persuaded to shift to a distance
further away from the unit. The structure and electrical safety audit of all
damaged buildings should be done and they should be repaired accordingly.
New construction should ideally be completed within two to three years.
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ANNEXURE - 01 MOCK DRILL OBSERVATION SHEET
Date :
Time :
Plant :
Incident Information :
Action By Name of Time – Observation

Person Hr/ Min
One Person Has observed the leakage. Mr.
Initial Response by him – shout _________
One person heard the shouting and rush Mr. ⮚

to IC and conveyed message to IC _________
IC reach at the site to observe the Mr. ⮚
situation _________
He and his first responder tried to stop Mr. ⮚
the leak _________
Information to Site Main Controller Mr. ⮚
________
Declaration of On-site emergency by Mr. ⮚
siren ________
Blow the emergency siren Mr. ⮚
________
Arrival of Spill & toxic controller Team Mr. ⮚
with Proper PPE/RPE and Arrival of First _________
& Rescue team
Arrival of Key personal & Engineering Mr. ⮚
service team _________
Plant shutdown and evacuation Plant IC ⮚
completed
Plant evacuated and assembled at AP Plant IC ⮚
Head count completed by Essential Mr. ⮚
Team _________
Spill & toxic control team started to stop Mr. ⮚
the leakage. _________
Leakage stopped Mr. ⮚
_________
Test for no leak Mr. ⮚
_________
All clear Mr. __ ⮚
SMC
Comments if any : Important and significant findings are as follows.
Observer Name: Mr. _________ / Mr. _________ / Mr. _________ Sign:
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ANNEXURE – 02 KEY PERSONS
Key Persons
Contact No.
Name / Designation
Mr. Shrikant Kamble - Site Main 9819934076

Controller
Ramprasad Kapse - Incident Controller

6359770157
Ankit Mittal - Deputy Incident Controller

9727782269
Vijay Pandey - Safety In-charge

6359770158
Dhaval Thoriya - Fire Fighting Team

9586753828
Sachin Kamble - First Aider Team

7069910048
Tushar Ruke - Spill Control Team

9727782324
Page 84
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ANNEXURE – 03 EMERGENCY RESPONSE & EVACUATION GUIDE OF

HAZARDOUS CHEMICAL
1. EMERGENCY RESPONSE & EVACUATION GUIDE FOR AMMONIA
Formula: NH3
Colourless gas or liquid with pungent odour
Flammable : Air – Ammonia mixture is inflammable

Flash Point : N/A
LEL- UEL : 16% - 25%
Toxic : Yes
IDLH : 300 PPM
TLV : 25PPM
I. General Response Action
● On-SITE: Stop Ammonia Leakage, if possible safely.

● Wear self contained Breathing Apparatus (SCBA) and use Ammonia emergency
kit.
● Stay upwind, out of low areas, and ventilate closed spaces before entering.
Evaluate the affected area to determine whether to evacuate or shelter-in-place by
taping windows and doors, shutting off outside air intakes (attic fans, etc.), and
placing a wet towel or cloth over the face (if needed).Earth-ground and bond all
lines and equipment associated with the ammonia system.
● Electrical equipment should be non-sparking or explosion proof.
● Use water spray / fog to disperse and dilute vapours
● Wear PVC Suit, Goggles, Hand gloves
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II. Evacuation Zone Dimensions

PROTECTIVE ACTION ZONE
III. Fire
● Ammonia is inflammable. Fire hazards of ammonia are moderate.

● Ammonia forms a flammable mixture with air within certain limits (16- 25%) by vol.
● Fire hazard increases in contact with oil or other combustible materials.
Suggested Action:
● To extinguish the fire using CO2, DCP or water sprays.

● Cool the leaking cylinder with large amt. of water.
● To control the fire, stop the flow of the gas if possible.
IV. Medical
Danger
● Skin Contact – Irritation, Burn may be very painful.

● Eye Contact; Highly painful irritation of eye & eyelids
● Watering of eyes.
● Serious lesions in eyes.
● Inhalation – Irritation of nose, eyes and throat.
● Difficulty in breathing
● Sudden death.
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Suggested Action:
● Immediately remove the victim from the affected area & take him to the nearest
shower.
● Immediately administer medical oxygen under low pressure using a pulmonary.
Antidotes: N.A.
V. Pollution
● Ammonia is harmful to aquatic life in very low concentrations and may be

hazardous if it enters water intakes.
● Local health and wildlife authorities, as well as operators of water intakes in the
vicinity, should be notified of water releases.
● Aquatic toxicity may occur at elevated concentrations.
● Ammonia does not concentrate in the food chain.
● The conversion of ammonia to nitrites/nitrates by bacteria in aquatic systems can
reduce the concentration of dissolved oxygen (referred to as nitrogenous oxygen
demand).
VI. Chemical Information
A) Chemical Reactivity:
Reactivity with Water:
Ammonia is rapidly soluble in water. When ammonia reacts with water, it forms
Ammonium Hydroxide
(NH3 + H2O 🡪NH4OH)
B) Reactivity with Common Material:

Ammonia is highly reactive with Sodium, Potassium at ordinary temp.
C) Polymerization:
Hazardous polymerization will not occur.
D) Combustion Products :
Hydrogen at very high temperatures: 15440F (8400C).
E) Properties:
● Physical State at 150 C and 1 Atm. Pressure: Gas
Page 88
● TLV: 25 PPM
● IDLH: 300 ppm
● Molecular weight: 17.03
● Boiling Points: -330 C at 1 atm
● Freezing Points: -780C
● Vapour Pressure: 7,600 mm Hg @ 250 C
● Vapour Density: (air=1) 0.597 @ 00 C
● Liquid Density: (Water=1): 0.6818
● Liquid Vapour conversion: 1:450
Page 89
ANNEXURE –04 POLLUTION CONTROL ARRANGEMENT
Water Pollution Control Air Monitoring
Type & No. of Other Lo No. & Type, Wind Instrum Log Book
Capacity sample Control g Places para direct ent &
of monitori Measures Bo of mete ion & Availabl Records
effluent ng ok sample rs & veloci e
treatment centers & & monitori frequ ty
plant its Re ng ency meter
frequenc cor centers of s
y ds tests
15 Each shift Concentrat Yes Final As Ambient Yes

KL/Day ed and toxic outlet of per Air
effluent is ETP MPC Monitor
treated at B As per
site. The norm wind
non- s indicat
concentrate or
d and non- which
toxic varies
effluent is promi
sent to nently
CETP for
treatment.
The
parameters
specified by
MPCB are
maintained
well within
the limits.
Page 90
II END OF THE REPORT II
Page 91

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ON SITE EMERGENCY PLAN

AARTI INDUSTRIES LTD.

CHAPTER- 3: ROLES AND RESPONSIBILITY

3.1 ROLES AND RESPONSIBILITY OF EMERGENCY RESPONSE PERSONNEL

3.1.1. Action Plan for Site Main Controller (SMC)

3.1.2. Action Plan for Incident Controller (I.C)

3.1.3. Roles & Responsibility of Deputy Incident Controller

3.1.4. Responsibilities of Night Duty Officer

3.1.5. Action Plan for Safety Department

3.1.6. Emergency Response Team (ER)

3.1.7. Emergency Control Centre (ECC): In-charge

3.1.8. Communication Officer (C.O)

3.1.9. Administrative Services

3.1.10. Action by Security Officer (S.O)

3.1.11. Action by Maintenance Department

3.1.12. Action plan for Nodal Officer of HR Department at Assembly Point

3.1.13. Role & Responsibility of Essential Employees (Workers)

3.1.14 Role & Responsibility of Key Personnel

3.2 EMERGENCY CONTROL CENTRE

3.3 ASSEMBLY POINTS

CHAPTER- 4: EMERGENCY MANAGEMENT PLANNING

4.1 POSSIBLE HAZARDOUS SCENARIO

4.2 PRE INCIDENT PLANNING

CHAPTER-5: COMMUNICATION ARRANGEMENTS

5.1 RAISING THE ALARM

5.2 DECLARING THE MAJOR EMERGENCY

5.3 TELEPHONE MESSAGES

5.5 COMMUNICATION OF EMERGENCY

5.6 TO KEY PERSONNEL OUTSIDE NORMAL WORKING HOURS

5.7 TO THE OUTSIDE EMERGENCY SERVICES AND THE AUTHORITIES

5.8 TO NEIGHBOUR FIRMS AND THE GENERAL PUBLIC

CHAPTER- 6: FIRE FIGHTING AND OTHER ARRANGEMENTS FOR EMERGENCY

6.1 AVAILABILITY OF FIRE FIGHTING FACILITIES

CHAPTER- 7: MUTUAL AID ARRANGEMENTS

CHAPTER- 8: INFORMATION ON THE PRELIMINARY HAZARD ANALYSIS

CHAPTER- 9: DESCRIPTION OF HAZARDOUS CHEMICALS AT PLANT SITE

CHAPTER-10: MAXIMUM CREDIBLE ACCIDENT SCENARIO & CONSEQUENCES

10.1 FIRE IN PLANT

CHAPTER- 11: EMERGENCY DUE TO NATURAL CALAMITIES

CHAPTER- 12: INTEGRATION OF ON-SITE EMERGENCY PLAN WITH DISTRICT OFF-SITE

12.1 PURPOSE OF THE OFF SITE EMERGENCY PLAN:

12.5 RECOVERY, RECONSTRUCTION AND REHABILITATION

ANNEXURE - 01 MOCK DRILL OBSERVATION SHEET

ON SITE EMERGENCY PLAN:

CHAPTER- 1: ORGANIZATION INFORMATION

Aarti Industries Ltd.

Full Name & Address of the

Full Name & Address of the

Maximum workers at a time

General (G) 174 194

Total Workers 225 25 250

First person to be contacted in case of emergency:

First person to be contacted in case of emergency

1. Mr. Shrikant Kamble Office 9819934076

2. Mr. Ramprasad Kapse Office 6359771057

3. Mr. Vijay Pandey Office 6359771058

CHAPTER- 2: SITE DEMOGRAPHY

2.1 DESCRIPTIONS OF DISTRICT MAP

North side Fabrication Company

East side MIDC Road

West side SKC Chemie Pvt Ltd.

South side Closed Factory