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1 | P a g e M/s Malbros International Pvt. Ltd., Village-Mansoorwal, Tehsil-Zira, Faridkot Road, District-Ferozepur, Punjab, India. Pin-142047

ON-SITE EMERGENCY PLAN

OF

M/s Malbros International Pvt. Ltd., Village-Mansoorwal, Tehsil-Zira, Faridkot Road, District-

Ferozepur, Punjab, India. Pin-142047

2016

-------Prepared By------

M/s Excellent Professional Solution, Second Floor, Nankana Complex,

Opposite Bus Stand, Ludhiana Contact-7355887070 & [email protected]

Annexure – 8 - On-site Emergency Plan

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TABLE OF CONTENTS

Sr. No. Desciption

Page No.

1. Introduction 05

2. Profile of The Company 07

3. General Information of Plant 10

4. Technical Features of Plant 13

5. Effluent Handling Section

17

6. Terminologies Related to Hazards

20

7. Different Phases of Disaster

23

8. Scope , Intent And Objective of Plan

24

9. Classification & Description of Emergencies

26

10. Emergency Mitigation & Preparedness 35

11. Emergency Response Procedures And Measures

37

12. Roles And Responsibilities

40

13. Fire Protection System & Sops

47

14 Communications Services & Infrastructure

54

i. Communication Flow Chart 54

ii. Flow of Information 55

iii. Siren Codes 56

iv. Details of the Emergency Control Centre (ECC) 56

v. Assembly Point and Their Area Coordinator 57

vi. Declaration of on-site and off–site emergencies 58

vii. Medical Facilities 58

viii. Evacuation 60

ix. Information to Public 60

x. Reporting of the Incident 60


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xi. Action after reporting of incident by the entity 61

xii. Termination of emergency 61

xiii. Emergency Recovery Procedures 62

xiv. Integration of the Onsite Emergency Plan (OEP) With The National Disaster Management Plan (NDMP)

62

xv. Security Threat Plan 64

xvi. Off-Site Emergency Plan 64

xvii. Plan Updation 66

xviii. Glossary 66

15 Hazard Identification, Hazard Analysis And Risk Assessment

67

16 Incident Prevention Measures 69

17 Post Emergency - Recovery Measures 70

18 Important Telephone Numbers 72

19 Fire Fighting Equipment & Personal Protective Equipment

73

20 Product Storage Capacity And Chemical Data

74

19 Fire Fighting Equipment & Personal Protective Equipment

73

20 Product Storage Capacity And Chemical Data

74

Annexxure-A : Material Safety Data Sheets of Hydrochloric Acid 75

Annexxure-B : Material Safety Data Sheets of Ammonium Hyrdoxide

76

Annexxure-C : Material Safety Data Sheets of Sulphuric Acid 77

Annexxure-D : Material Safety Data Sheets of Ethanol 78

Annexxure-E : Material Safety Data Sheets of Diesel 83

Annexxure-F : Incident Reporting Format –For Compilation 85

Annexxure-G : Resource Mobilization (Men and Equipment) to be Kept Ready in Due Course of Time

88

Annexxure-H: List of Relevant Statutes on Management of Hazardous Substances

90

Annexxure-I: The Important Roles And Responsibilities Of Various Stakeholders

91

Annexxure-J: Plant Layout with marking of Assembly Points

92


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LIST OF ANNEXXURES

Annexxure-A : Material Safety Data Sheets of Hydrochloric Acid Annexxure-B : Material Safety Data Sheets of Ammonium Hyrdoxide Annexxure-C : Material Safety Data Sheets of Sulphuric Acid Annexxure-D : Material Safety Data Sheets of Ethanol Annexxure-E : Material Safety Data Sheets of Diesel Annexxure-F : Incident Reporting Format –For Compilation Annexxure-G : Resource Mobilization (Men and Equipment) to be Kept Ready

in Due Course of Time

Annexxure-H: List of Relevant Statutes on Management of Hazardous Substances

Annexxure-I: The Important Roles And Responsibilities Of Various

Stakeholders Annexxure-J: Plant Layout with marking of Assembly Points


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1. INTRODUCTION The adoption of new technologies has worked marvels for industry, while consumer has been benefited from this commercial boom; the nation has also been able to set a brisk pace of industrial growth. This augurs well for everyone. However, there is a need to be cautious in dealing with these technological changes. If not handled properly, they can create several environmental problems: contamination of water resources, coal and ash dust, mist, particulate etc. Atmospheric changes as well as loss of precious plant and animal life. These hazards also endanger human life. Chemicals which are hazardous like Acids, Liquid Ammonia, HCL, H2SO4& Alum materials which are inflammable like Lubricating and Servo Oil, Rice Husk, Light Diesel Oil are being more widely used in distillery plants. Improper handling of these materials, may lead to uncontrollable hazards, costly accidents and in rare cases may lead to disasters. In the wake of such disasters, legislation has been enacted to tighten safety norms. But there is still scope for system failures. In order to generate emergency plan, each part / section of the plant of the complete plant as a whole need to be studied and analyzed critically from safety point of view. To control effectively the rise of such situations, it is imperative to plan “ON –SITE EMERGENCY PLAN”. Awareness of total plant operations and strict adherence to environmental safety standards is an integral part of our operations. An environmental protection department has been established and working efficiently to monitor all environmental related activities. In managing an emergency (fire, explosion and hazardous release) one has to consider whether the life and health of the employees, contract staff & workers working in the plant are endangered as also is there any damage to property.This manual will generate awareness among all the employees, contract staff & workers, working in plant premises, to adhere to environmental safety standards and also provide information for managing any emergency effectively. After the incident of Bhopal gas disaster and supreme court directions in case of M/S. Sriram Foods and Fertilizers, the Govt. of India has made some important amendments to the Factories Act 1948 in the year 1987 with incorporation of special provisions relating to hazardous process and a new chapter i.e. Chapter IVA under which the provisions like sections 41A, 41B, 41C, 41D, 41E, 41G & 41H


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covering all hazardous process industries are added. Under the provision of Section 41-B (4) every occupier shall with the approval of the Chief Inspector of Factories draw up an On-site Emergency Plan and detailed disaster control measures for his factory and make known to the workers employed therein and to the general public living in the vicinity of the factory the safety measures required to be taken in the event of an accident taking place. This is the statutory provision laid down in the act for preparation of On-site Emergency Plan to control disaster in the factories. Any accidents may cause emergency and it may lead to disaster, which may cause heavy damage to plant, property, harm to person and create adverse affects on production. The manufacturing process carried out in M/s Malbros International Pvt. Ltd., Village-Mansoorwal, Tehsil-Zira, Faridkot Road, District-Ferozepur, Punjab, India comes under the category of Hazardous Process at Item Number 12 as “Fermentation Industries (Distilleries and Breweries)” in The First Schedule made

under the Section 2 (cb) of the Factories Act, 1948. The need of the onsite emergency plan was felt due to the statutory requirement as applicable to the hazardous process under different legislations by State as well Central Governments. This Onsite Emergency plan is made to comply with the Section 41-B(4) of the Factories Act, 1948 as applicable to this plant. Although the similar provisions regarding onsite emergency plan also exists under Rule 13 of the Punjab Control of industrial Major Accident Hazards Rules, 1993 and Rule 13 of Manufacture, Storage and Import of Hazardous Chemicals Rules, 1989 but these rules are only applicable to MAH units which derive this designation if they store or process some threshold quantities of different chemicals as specified in schedules annexed to PCIMAH Rules-1993 & MSIHC Rules-1989. Also it is recommended to participate actively and become a active member of different meetings or mock drills conducted by district and local crisis groups constituted under Emergency Planning, Preparedness & Response for Chemical Accidents Rules-1996. Along with this regular interaction with other group members, departments, governmental agencies and in particular office of Directorate of Factories which will give exemplary exposure in handling different types of emergencies.


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2. PROFILE OF THE COMPANY Company introduction and its work profile The Oasis Group of Companies‟ is a fast growing conglomerate having diversified

business operations in the field of Distilleries, Breweries, Hospitality, Diamonds, Exports and Government Contracts. Oasis Group in the year 1987. Since, then the Oasis Group has a remarkable growth and within a span of almost 30 years has emerged to be one of the fastest growing liquor group. Pride of Indian liquors, „The Oasis Group of Companies‟ was incepted in the year

1987. Since then the Oasis Group is growing by leaps and bounds operating in the field of Distilleries and Breweries. The Oasis Group has a turnover of Rs. 1500 crores in 2014-15 and targets to achieve Rs. 2000 crores by the next financial year. The Oasis Group presently operates 5 distilleries across the country with a collective production of approximately 20 crores litres of Grain Based Extra Neutral Alcohol, making it one of the largest Grain Spirit producers in the Country. The Group enjoys a very important position amongst the liquor companies in Punjab by virtue of owning two „State-of-the-Art‟ Grain Distilleries at Ferozepur

and Bhatinda and a bottling unit at Sandhe Hasham-Ferozepur, further complemented with substantial wholesale and retail outlets which has helped the Group cover the complete channel of liquor distribution thereby making it a major player in Punjab. Oasis Group is a significant player amongst the emerging Indian spirits market with their International Quality Grain based spirits, Indian Made Foreign Liquor with consistency of quality, delivery, superior consumer experience, thereby creating maximum value amongst its connoisseurs. With the introduction of its Premium Whisky-Blue Patrol, an Imported Vatted Malt Scotch blend this year, the Oasis Group stands firm with yet another launch of Super Premium Whisky with dynamic Packaging and blend by next year. The Oasis Group now plans to broaden its brand base by entering into Semi premium & Premium Segments in Whisky, Brandy and White Spirits. Presently the Oasis Group operates in approximately 18 states in India, besides Union Territories and is also exporting to a number of countries. The Oasis Group operates in most of the prominent civil Indian Made Foreign Liquor markets. Since the Oasis Group is a preferred supplier to the Canteen Stores Department (CSD)


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which caters to the Esteemed Indian Armed Forces, the Oasis Group enjoys an absolute PAN India presence for its IMFL brands. The Oasis Group provides different varieties of whiskey, vodka, rums scotch etc. The Oasis Group supports old age homes, hospitals etc. The Oasis Group has already launched a Pure Herbal Diet Whisky which is blended out of Aloe Vera, Ginseng & Garcinia. The Oasis Group hopes to project this blend as a health conscious Whisky. The group is in the process of launching a tripled distilled Green Apple and Orange flavored Vodka in the Premium Segment shortly, besides a Premium Grapes Spirit Brandy for the South Indian market. Oasis Group is the leading group having five state of the art distilleries in India that produces Extra Neutral Alcohol (ENA) from grain. The Oasis Group presently operates 5 distilleries across the country with a collective production of approximately 18 crores litres of Grain Based Extra Neutral Alcohol, making it one of the largest Grain Spirit producers in the Country. Oasis Group boasts of providing the finest quality of ENA that is formulated as per industrial norms and standards. The Oasis Group also exports Extra Neutral Alcohol in different parts of the world. Oasis Group is one of the largest IMFL (Indian Made Foreign Liquor) producers in the country. It is a significant player amongst the emerging Indian spirits market with its International Quality Grain based spirits, Indian Made Foreign Liquor with consistency of quality, delivery, superior consumer experience, thereby creating maximum value amongst its connoisseurs. Oasis Group is first of its kind in the country which has sophisticated in-house facilities to produce molasses and non-molasses based neutral spirits from completely automated Distillation Plants. Oasis group is the top manufacturer of producing Country Liquor in India with a sizeable market share. It aims to provide premium quality Country liquor to an ordinary man, who savors its taste, at the most reasonable rate, Oasis Group aims to create a stronghold in the country liquor market and intends to extend the depth of supply coverage for reaching untapped markets and pursue growth by increasing their penetration in more states and setting up more production units in other locations. Oasis Group has almost track record of manufacturing quality ethanol,


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extra neutral alcohol and producing quality ethanol, rectified spirits, extra neutral alcohol and potable country liquor. Oasis Group specializes in making Distillers Dried Grain Soluble (DDGS), which is a cereal by product of the ENA production process. The Oasis Group is one of the largest producers of high nutrient DDGS in India with protein content of minimum 45%. DDGS is an excellent feed ingredient for livestock and poultry diets. Oasis DDGS are highly digestible, increases efficiency, enhances palatability and lowers toxicity. Our state-of-the-art distilleries are completely compliant with top-notch quality norms. Moreover, great care is taken to maintain international standards of hygiene and handling.


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3. GENERAL INFORMATION OF PLANT

The Malbros International Pvt. Ltd.layout is shown in the figure below.

Incorporated in 2007, Malbros International Pvt. Ltd. is a leading alcoholic beverage company, which accounts for the manufacture of a special range of branded Whiskey, Country Liquor, Rum, Vodka and Gin. MIL Distillery is one of the most efficiently-run distilleries in India manufacturing high grade Extra Neutral Spirit (ENA) from Grain with a production capacity of 1.2 Million Litres per annum of Grain Neutral Spirit. It is a state-of-the-art grain based distillery at „Zira‟ district

Ferozepur, Punjab. It is an integrated plant having facilities for producing Rectified Spirit ENA 90000 and Bottled Liquor. The Unit is self-sufficient in meeting the fuel and power requirement by way of backward integration of utilizing its effluent for generating the bio-gas which, in turn, is utilized for generating the steam and power for its captive requirement.MIL Distillery also manufactures various brands of IMFL and Country Liquor. In dry milling, the entire starchy grain is first ground into flour, referred to in the industry as “meal,” and processed without separating out the various component parts of the grain. The meal is slurried with water to form a “mash.” Enzymes are


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added to the mash to convert the starch to dextrose, a simple sugar. Ammonia is added for pH control and as a nutrient to the yeast. The mash is processed in a high-temperature cooker to reduce bacteria levels ahead of fermentation. The mash is cooled and transferred to fermenters where yeast is added and the conversion of sugar to ethanol and carbon dioxide (CO2) begins. The fermentation process generally takes about 40–50 hours. During this part of the process, the mash is agitated and kept cool to facilitate the activity of the yeast. After fermentation, the resulting “beer” is transferred to distillation columns where

the ethanol is separated from the remaining “stillage.” The ethanol is concentrated

to 190 proof using conventional distillation and then is dehydrated to approximately 200 proof in a molecular sieve system. The stillage is sent through a centrifuge that separates the coarse grain from the solubles. The solubles are then concentrated to about 30 percent solids by evaporation, resulting in Condensed Distillers Solubles (CDS) or “syrup.” The

coarse grain and the syrup are then dried together to produce Dried Distillers Grains with Solubles (DDGS), a high quality, nutritious livestock feed. The CO2 released during fermentation is captured and sold for use in carbonating soft drinks and beverages and manufacturing dry ice. POSTAL ADDRESS OF FACTORY: Malbros International Pvt. Ltd. Village Mansoorwal, Tehsil Zira District Ferozepur Punjab, India. 142047 Phone: 01682- 262107, Fax: 01682-262007 Cell: 099148-00006, 098140-94394 E-mail: [email protected] REGISTRED OFFICE: Oasis group of companies HD-8, Pitampura, Near Madhuban Chowk, New Delhi - 110026, India Phone:+91 - 011-27312685, 011-25229720, 011-25229721Fax: 011-27317765 Cell:+91 - 9899450255, 9873900090 Email: [email protected]


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mailto:[email protected]


Demographic Information of Plant

The site for the Distillery and Bottling Project is located on Zira-Faridkot road (N.H. 54) about 8.5 km from Zira town towards Faridkot, Ferozepur District. It is situated near about 2.4 km to Sugar Mill Zira. The site falls under seismic zone IV. The average mean daily maximum ambient temperature is about 350C and the relative humidity ranges between 25%-75%. The different demographic establishments that fall under 5km from plant are: -

S.No Name of Villages 1 Ratol Rohi 2 Mansoorwal Kalan 3 Mansoorwal 4 Sunehar 5 Bhandala purana 6 Mahian Wala Kalan 7 Wakilan Wala

Working Hours:

Shifts Hours Employees strength in each shift

1St Shift 6:00am to 2:00pm 40 2nd Shift 2:00pm to 10:00pm 40 3rd shift 10:00pm to 6:00am 40 General 9:00am to 6:00pm 100

(General Shift With lunch break from 1.00PM to 2.00PM and 30 Minutes by rotation in other regular shifts) Weekly Holiday for General Shift: Sunday Weekly Holiday for Shift: Any one of the week day during the Week


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4. TECHNICAL FEATURES OF PLANT

1. Grain Storage: Grains are procured from various sources, such as FCI Storage godowns through agencies and are unloaded into large Storage Silos after Pre-Cleaning. Storage Silos are specially designed to keep the Grains in good condition for longer durations and also avoid its deterioration and theft, etc. It is being proposed to have 30 – 45 days of Grain Storage facility in the Distillery.

2. Grain Cleaning, Milling and Flour Handling: The grain is lifted in bucket elevators, screened followed by removal of stones and iron matter. Cleaned Grains are then milled using dry milling process in Hammer Mills. The flour is fed through the bucket elevator and conveyed to the Batch Tipping Machine through a Screw Conveyor. The flour addition is metered through the Batch Tipping Machine with load cell arrangement, before transferring the flour to the Slurry Tank through another Screw Conveyor (pre-masher) for slurry preparation process. It is being proposed to have 4 x 16 TPH as milling paraphernalia for this Distillery.

3. Slurry Preparation & Liquefaction: Grain flour and process water is fed at controlled rate to Initial Liquefaction tank. Mixed slurry is taken to the Initial Liquefaction Tank where additional quantity of water is added as per requirement. Viscosity reduction Enzyme and stabilizing chemicals and a portion of liquefying enzyme are also added at this stage. This slurry is then “cooked” in the jet cooker. The slurry is continuously pumped to a steam jet cooker where high-pressure steam rapidly raises the slurry temperature. The mixture of slurry and steam is then passed through the Retention Vessel. The retention vessel has sufficient capacity to provide the desired retention time at a given flow rate. The cooked mash is discharged to a Flash Tank. The cooking process, accomplished in the above manner, converts the slurry into a hydrated, sterilized suspension and is therefore susceptible to enzyme attack for liquefaction. The gelatinized mash from the Flash Tank is liquefied in the Final Liquefaction Tank where liquefying enzyme (alpha-amylase) is added. The liquefied mash is cooled in Mash Cooler and transferred to Saccharification cum fermentation section. This process initiates the formation of sugar. The gelatinized mash from the Flash Tank is liquefied in the Final Liquefaction Tank where liquefying enzyme (alpha-amylase) is added. The liquefied mash is cooled in Mash Cooler and transferred to Saccharification cum Fermentation section.


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4. Hi-ferm-Nm Saccharification and Instantaneous Fermentation: Yeast Activation:

Yeast seed material is prepared in water-cooled Yeast Activation Vessel by inoculating sterilized mash with Active Dry Yeast. Optimum temperature is maintained by cooling water. The contents of the Yeast Activation Vessel are then transferred to Fermenter.

5. Saccharification & Instantaneous Fermentation: The Liquefied starch slurry comprising Dextrins is partly taken for Yeast development in Yeast Activation vessel and majorly transferred into the Fermenter. Amyloglucozydase and other nutrient Enzymes are first added to Saccharify the Starch Slurry causing formation of Sugars. Immediately, the Active Yeast is introduced in the system for simultaneous Fermentation. The process of fermentation is to convert the fermentable substrate into alcohol. To prepare the mash for fermentation, it may have to be diluted with water. The pH of the mash is adjusted by the addition of acid. Yeast is available in sufficient quantity to initiate fermentation rapidly and complete it within the cycle time. At the start of the cycle, the fermenter is charged with mash and contents of the Yeast Activation Vessel. Significant heat release takes place during fermentation. This is removed by passing cooling water through the Fermenter PHE‟s to maintain an optimum

temperature. The recirculating pumps also serve to empty the fermenters into Beer Well. After the fermenters are emptied, they are cleaned with water and caustic solutions and sterilized for the next batch. The carbon dioxide evolved during the process is vented to atmosphere after recovery of alcohol in a scrubber.

6. Ethanol Distillation:

Fermented wash from wash holding tank T-01 is pumped by wash feed pump P-01 to the top of degassing column (C-2) after preheating the same in beer heater E-02 and spent wash heat exchanger E-01. The vapors along with non-condensable gases from the top of degassing column (C-02) are rectified in Heads column (C-03), to expel the high volatiles, technically known as heads. Bottom liquid from the degasser flows into analyzer column (C-01) where alcohol is stripped from the liquid. The liquid from bottom of analyzer column (C-01) is completely stripped of alcohol and is pumped out by thick slop discharge pump P-02 through heat exchanger E-01 where it preheats the fermented wash before it enters degassing column. The slop from the analyser column will be feed in to decanter. The dilute alcohol vapors from near the top of analyzer column (C-01) are condensed first in


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beer heater (E-02) while exchanging heat with wash feed and then in analyzer condenser (E-03). Degasser and analyzer operate under vacuum. The condensate from E-02 and E-03 is collected in Rectifier Feed Tank V-02. The vapors for stripping alcohol are generated from analyzer column bottom liquid in the analyzer column re-boiler (E-04) by using the rectified column top vapors, as discussed subsequently. Vapors from the top of heads column (C-03) are condensed in heads column condenser (E-06) and then in head column vent condenser (E-07). Part of the condensate is returned to column C-03 as reflux while a small portion is taken out as an impure spirit cut. Liquid from bottom of C-03 is also taken into Rectified feed tank V-02.Dilute alcohol water mixture from rectifier feed tank (V-02) are pumped by rectifier feed pump (P-04) through rectifier feed pre-heater E-11 in to rectifying column (C-04). Rectifier and its associated equipment work under pressure so that these vapors can supply the necessary heat for generating the vapors. The condensate from E-04 is then pumped as Reflux to rectifying column C-04. Rich alcohol vapors at a concentration of 95.5% v/v from top of rectifying column (C-04) are condensed first in Analyzer (E-04) and then in Reflux Vent Condenser (E-05). The liquid from E04 and E-05 are collected in Rectifier Reflux Tank (V-01). Part of the liquid from E-05 may be drawn off as impure spirit. The impure spirit cut will be maintained as little as possible to maintain aldehyde levels to meet the required limits in Absolute Alcohol. Liquid from the reflux tank (V-01) is pumped by Product Pump (P-03) partly as product and partly as reflux to the top of the Rectifying Column (C-04). The necessary rectifying vapors to C-04 are generated by boiling the C-04 bottom liquid in Rectifier Column Re- boiler E-08 using medium pressure steam. Some side streams are drawn from rectifier column as light and heavy fractions of higher alcohols called fusel oils and cooled in fusel oil coolers E-09 and E-10 and are mixed with water and allowed to separate out in fuel oil separator F-01. All vents from E-03, E-07, V-02 and E-05 are connected to Vent Gas Absorber (C-05) where the vent gases are scrubbed with water to recover entrained alcohol. The scrubber water is used for washing the fuel oils in fuel oil separator to recover alcohol from the fuel oil fractions. The absorber vent is connected to vacuum pump (G-01) which is used to create vacuum in the analyzer and degasser. Absolute alcohol is manufactured by dehydration of Rectified Spirit. The process adopted here is based on Pressure Swing Adsorption (PSA) system using Molecular Sieves (3-A). The flow scheme is shown in above referred flow diagram. Rectified spirit, after preheating by waste hot streams, is vaporized and superheated in E-03 and E-04 by using medium pressure steam at 6 Kg/cm2g pressure. Hot vapors at kg/cm² g pressure and 130° C temperature pass through PSA column S-01A/S-01B where the water vapors are retained while water free


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alcohol is released as vapors. The vapors are condensed in E-07 and E-08 and collected as Absolute Alcohol. When the molecular sieve bed is saturated with water the alcohol vapors are shifted to the other tower and the first tower is taken for regeneration. Regeneration is done first by pressure releasing and creating vacuum and then by elutriating with dehydrated alcohol vapors from the tower in dehydration operation. The vapors are condensed in E-06 and E-05 and the vent vapors are recovered through scrubber C-02. Vacuum can be created vacuum by P-04. (Eductor may also be considered for this duty). Product is cooled in E-09 and transferred to Absolute Alcohol receiving tank and then on to storage tank. This process utilizes the following columns namely Analyser, Degassifier, Aldehyde, Pre-Rectifier Column, P/R Stripper Column, Rectifier-cum Exhaust, Extractive Distillation (ED) Column, Fusel Oil Concentration Column and Simmering Columns. The Analyser, Degassifier, Aldehyde, Pre-Rectifier Columns are operated under Vacuum whereas Simmering, Extractive Distillation, FOC Columns are operated under Atmospheric condition. The Rectifier-cum-Exhaust Columns are operated under Pressure.The energy requirement for Analyser Column & Pre-rectifier is met by Rectifier Column top vapours. The Rectifier Column top vapours are condensed in a thermo-siphon reboilers connected to a flash tank and then flash vapours out of soft water feed are injected into Analyser Column. The energy requirement of the Simmering Column is met by the top vapours of Extractive Distillation Column while that of the FOC Column is through direct steam. In the distillation scheme offered, all Columns are designed for all the products.

7. Alcohol Daily Receivers & Bulk Storage:

Alcohol is first taken to Daily receiver storage tanks, which is based on the State Excise laws, storage for three days considering the weekly holidays of two days. Thereafter, the alcohol is transferred to Bulk Storage Tanks after taking the daily receiver Dip. This is transferred using flameproof pumps. Final dispatch of alcohol is metered and again is carried out using special flameproof pumps. The Bulk Spirit Storage is proposed to be set up for 30 days.


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5. EFFLUENT HANDLING SECTION

1. Decantation Section: Decantation section comprises of Centrifuge Decanters, operating at high rpm which are used for separation of suspended solids from Spent Slops coming out of Distillation section. The Wet cake thus separated has 30-35% w/w solids, as removed from bottom of Decanters. This is directly loaded on the trolleys parked below. Thin slops coming out of Decanter are collected in a tank and are transferred for part recycle & further for Evaporation into thick syrup.

2. Integrated Evaporation Section: The suggested treatment scheme is a 5 FF and 2 Forced circulation Evaporation Plant forThin Slops Evaporation. The following points will elucidate the basic working principle:

Shell & Tube type Evaporators with highly efficient liquid distributor working on the principle of Falling Film Evaporation have been used, with Plate type Pre-heaters for preheating of FEED stream which serves the purpose of energy conservation.

Simmering and ED column vapour is fed to the fifth and sixth effect evaporator shell side at the given pressure and temperature as the heating medium.

The Feed from the Feed balance tank is taken to the PHCOND to make the best heat recovery.

The Feed after getting heated to the predetermined temperature in preheater is fed from the first effect evaporator which is Falling Film Evaporator -1

The flow path isgiven below.

INLET FEED – E5 – E6-E3-E4- E7-E2 – E1 – OUTLET PRODUCT Vapour generated in1st effectVLS (VapourLiquidSeparator) are used as heat

source in the 2nd effect. A Shell & tube type Multi-pass Surface condenser is employed for

condensing the shell side vapours. The Pure and the process condensate are collected in receiving vessels. Highly efficient operating pumps will be provided for pumping the required

fluid.The operation of the plant will be under vacuum. Vacuum is created with the help of a waterring vacuum pump.

The plant will have high level of automation to get consistent output at required concentration.


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The system operates under vacuum. Water-ring vacuum pumps are used to maintain a desired vacuum.

Cooling water from cooling tower is used in the surface condensers for condensing the vapours.

CONCLUSION

The thick syrup thus obtained is mixed with the Wet Cake obtained from Decanter Centrifuges using specially designed Ribbon type mixer and this enriches the protein content in the fibrous suspended solids separated earlier in Decanter. This Protein & Fiber rich DWGS is directly sellable as Cattle/ Poultry Feed. However, in order to increase the shelf life of such by-product, it is necessary to dry the product,with minimum possible moisture content.

System Description For DWGS Dryer

Wet distiller‟s grains shall be fed into the dryer housing at controlled rate through a suitable feeding system. The Rotary Tube Bundle is enclosed in an insulated dryer housing and on its outer flights are fixed. Dry saturated steam is to be supplied to the tube bundle through rotary joint at one end & the condensate is discharged through rotary joint mounted at other end. During the course of rotation, these flights pick up the material and shower them on to the tube bundles. The heat transfer is primarily by conduction. The water vapours are exhausted through an Exhaust Blower & passed through a cyclone separator for separating fines.Dry product partially recycled back to Feed conditioner for feed conditioning through Product Screw & Recycle Conveyor. Entire operation of the Dryer is controlled through Control panel.

System description for cooling & conveying

DWGS below product screw is discharged into charging hopper of pneumatic conveying system.

Rotary feeder feeds it into the conveying line. Ambient air is used for conveying. The material gets conveyed to product collector &discharged from rotary

discharge valve. Exhaust air is vented to atmosphere. The conveying system is lean phase suction type, using centrifugal blower as

prime mover. The conveying air quantity is designed considering cooling requirement & to cool the product before discharge.


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6. TERMINOLOGIES RELATED TO HAZARDS

Following are the list of definitions used in this document, unless the context otherwise requires: -

a) “boiling liquid expanding vapour explosion (BLEVE)” means the violent rupture of a pressure vessel containing saturated liquid or vapour at a temperature well above its atmospheric boiling point and the resulting flash evaporation of a large fraction of the superheated liquid which produces a large vapour cloud which burns in the form of a large rising fireball due to ignition;

b) “chief incident controller” means the person who assumes absolute control of the unit and determines action necessary to control the emergency; c) “disaster” means an occurrence of such magnitude as to create a situation in

which the normal patterns of life within an industrial complex are suddenly disrupted and in certain cases affecting the neighborhood seriously with the result that the people are plunged into helplessness and suffering and may need food, shelter, clothing, medical attention protection and other life sustaining requirements; d) “disaster management plan “mean a well-coordinated, comprehensive response plan to contain loss of life, property, environment and provide speedy and effective recovery by making the most effective use of available resources in case of a disaster; e) “emergency” means a situation or scenario which has the potential to cause

serious danger to persons, environment or damage to property and which tends to cause disruption inside or outside the premises and may require the help of outside resources; f) “hazard” means an event related to the property of substance or chemicals with a potential for human injury, damage to property, damage to the environment, or some combination thereof; g) “incident” means an unplanned or unintended or intended event having potential

to cause damage to life, property and environment;


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h) “incident record register” means a register containing complete information

pertaining to all incidents covering near miss, and all other incidents leading to Level-I, Level-II and Level-III emergencies; i) “leak” means release or discharge of a dangerous chemicals or substances or

material into the environment; j) “Level-I emergency” means an emergency as defined under below; k) “Level-II emergency” means an emergency as defined under below;

l) “Level-III emergency” means an emergency as defined under below;

m) "occupier” of an installation means the person who has ultimate control over

the affairs of the installation; n) “off-site emergency” means an emergency that takes place in an installation and

the effects of emergency extends beyond the premises or the emergency created due to an incident, catastrophic incidents, natural calamities, etc. It no longer remains the concern of the installation management alone but also becomes a concern for the general public living outside and to deal with such eventualities shall be the responsibilities of district administration; o) “off-site emergency plan” means a response plan to control and mitigate the

effects of catastrophic incidents in above ground installation (AGI) or underground installations (UGI) or road transportation. This plan shall be prepared by the district administration based on the data provided by the installation(s), to make the most effective use of combined resources, i.e. internal as well as external to minimize loss of life, property, environment and to restore facilities at the earliest; p) “on-site emergency” means an emergency that takes place in an installation and

the effects are confined to the Installation premise‟s involving only the people

working inside the plant and to deal with such eventualities is the responsibility of the occupier and is mandatory. It may also require help of outside resources; q) “on-site emergency plan” means a response plan to contain and minimize the

effects due to emergencies within the installations which have a potential to cause damage to people and facilities within the installation premises;


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r) “risk” means the chance of a specific undesired event occurring within a

specified period or in specified circumstances and it may be either a frequency or a probability of a specific undesired event taking place; s) “risk analysis” means the identification of undesired events that lead to the

materialization of a hazard, the analysis of the mechanisms by which these undesired events could occur and, usually, the estimation of the extent, magnitude, and likelihood of any harmful effects; t) “risk assessment” means the quantitative evaluation of the likelihood of

undesired events and the likelihood of harm or damage being caused by them, together with the value judgments made concerning the significance of the results; u) “risk management” means the programme that embraces all administrative and

operational programs that are designed to reduce the risk of emergencies involving acutely hazardous materials. Such programs include, but are not limited to, ensuring the design safety of new and existing equipment, standard operating procedures, preventive maintenance, operator training, incident investigation procedures, risk assessment for unit operations, emergency planning, and internal and external procedures to ensure that these programs are being executed as planned; v) “site incident controller” means the person who goes to the scene of the

emergency and supervises the actions necessary to overcome the emergency at the site of the incident; w) “spill” means an unintended release or discharge of hydrocarbon or any other

dangerous liquid into the environment; x) “transport emergency (TREM) card” means a card containing details about the

nature of hazards, protective devices, telephone numbers and actions related to spillage, fire, first aid and other details of national and international (UN) numbers or signage which is common in India and abroad; y) “unconfined vapour cloud explosion (UVCE)” means the formation of vapour cloud due to release of significant quantity of liquefied hydrocarbons into the atmosphere and its explosion due to ignition which may cause high over pressure and low pressure that cause very heavy damage.


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7. DIFFERENT PHASES OF DISASTER

In view of the hazards associated with Fermentation Industries (Distilleries and Breweries) it is required to develop on-site emergency plan. Such plan will ensure establishment of a system, which would make optimum use of available resources for speedy containment of the disaster, protecting the health and safety of people, nearby residences and workers as well as minimizing damage to property and environment. There are other external agencies involved in the activities associated with disaster situation e.g. Civil Administration, Fire services, Medical, Police, Army, Voluntary organizations etc., which calls for an organized multi-disciplinary approach to disaster management. Warning Phase Many disasters are preceded by warning signals like liquid hydrocarbons leaks developing into vapor cloud, weather forecast giving advance warning of meteorological disasters, uncontrolled chemical reactions ending up in explosion etc. Warning phase provides a cushion to put into action the remedial measures to counter the disaster.

Period of Impact This is the period when the disaster strikes and very little can be done to minimize its impact. This period can last for a few seconds (as in case of explosions) to many days (as in case of tank fire, natural calamities etc.) Rescue Phase The rescue phase starts immediately after the impact and continues until necessary measures are taken to rush help to combat the situation and to evacuate people to safer places.

Relief Phase During this phase relief measures are organized internally. External help can also be summoned to augment the internal resources. Rehabilitation Phase This is the final phase in disaster management, during this period, estimating the damages, payments of compensation, rebuilding the damaged property etc. are done. Inter disciplinary effort, total co-ordination within the organization is required to be implemented and aid from statutory bodies, experts can be availed.


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8. SCOPE , INTENT AND OBJECTIVE OF PLAN

SCOPE The scope shall cover:

(i) the identification of emergencies; (ii) the mitigation measures that attempt to reduce and eliminate the risk or

disaster; (iii) the preparedness that to develop plans for actions when disaster or

emergencies occur; (iv) the responses that mobilize the necessary emergency services including

responders (primary, secondary and tertiary) like fire service, police service, medical service including ambulance, government as well as non-governmental agencies;

(v) the post disaster recovery with aim to restore the affected area to its original conditions;

INTENT It is intended to apply this document –

(a) to develop an ONSITE EMERGENCY PLAN (OEP)that should be concise and informative so that members of the emergency control organization should be able to quickly refer to the action plan to determine important functions that are being carried out;

(b) to manage an emergency and not to use OEP just as reference material for training and shall be made applicable -

(i) to prevent casualties - both on-site and off-site; (ii) to reduce damage to property, machinery, public and environment; (iii) to develop a state of readiness for a prompt and orderly response to an

emergency and to establish a high order of preparedness (equipment, personnel) commensurate with the risk;

(iv) to provide an incident management organogram with clear missions and lines of authority (incident command system, field supervision, unified command);

(v) to ensure an orderly and timely decision-making and response process (notification, standard operating procedures);

(vi) to maintain good public relations;


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Note: No two locations shall be identical in respect of layout, surroundings, products, storage quantities, meteorological data etc. Therefore, ONSITE EMERGENCY PLAN (OEP) will be location specific as per the available resources. OBJECTIVE Objective of the plan are to provided a system, capable of taking fast and effective action in a emergency situation in order to :-

i. Safe guard the factory personnel inside & public outside the factory. ii. Effect the rescue & treatment of causalities.

iii. Safe guard the property and environment. iv. Bring the incident under control. v. Treatment of casualties, Head count, and information and assisting relatives.

vi. Provide authorities information to the news media. vii. Ensure rapid return to normal operation after emergency.

viii. Preserve relevant records and equipment‟s the subsequent inquiry. ix. Developing factory personal to ensure its at no panic on such occasion of

safe, skilled, action will minimize the casualities, injuries and damages of other nature.

x. To maintain & culminate good image in public & National interst. Elimination will require prompt action by operations and works emergency staff using, for example, fire–fighting equipment, water sprays etc. Minimizing the effects may include rescue, first aid, evacuation, rehabilitation and giving information promptly to people living nearby.


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9. CLASSIFICATION & DESCRIPTION OF EMERGENCIES

The views of the possible hazards that can arise out of the daily operations in the

distillery plant, various measures are adopted to prevent the occurrence of a major

accident. This comprises of:

Built in safety measures, alarms, trips and interlocks etc.

Standard safe operating and maintenance procedures permit system etc.

Training of all the involved staff in normal and emergency operating procedures.

Training of all employees in safety, fire fighting and first aid.

However, in spite of these precautions, it is required to foresee situation of major

accident and plan for taking timely action to minimize the effects of such incident

on the safety and health of persons working in the plant as well as those living

around the premises. Generally, Emergencies can be categorized into three broad

levels on the basis of seriousness and response requirements, namely: –

Level 1: This is an emergency or an incident which

a) can be effectively and safely managed, and contained within the site, location or installation by the available resources;

b) Has no impact outside the site, location or installation. Level 2: This is an emergency or an incident which –

a) cannot be effectively and safely managed or contained at the location or installation by available resource and additional support is alerted or required;

b) is having or has the potential to have an effect beyond the site, location or installation and where external support of mutual aid partner may be involved;

c) is likely to be danger to life, the environment or to industrialassets or reputation.

Level 3: This is an emergency or an incident with off-site impact which could be catastrophic and is likely to affect the population, property and environment inside and outside the installation, and management and control is done by district


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administration. Although the Level-III emergency falls under the purview of District Authority but till they step in, it should be responsibility of the unit to manage the emergency. Level-I and Level-II shall normally be grouped as onsite emergency and Level-III as off-site emergency according to the hazards/risks associated as follow: Sr No Type of

Emergency Applicable Plan

Causes of Emergency

1 Level – I Onsite

Emergency Plan

Small Fire due to:

Spilling from the flanges/Pipeline/

Hammer Blinds/Gate Valves

Pinhole leakage from Pipelines

Failure of gasket resulting in leakage

Fire in Electric Panels, Oil Room and

alcohol storage

Hazards in Waste treatment processes

Minor Injuries & other risks in Cleaning

of barrels, which have held chemical

substances

Exposure to fugitive dust, noise, and

other emissions

Housekeeping practices requiring

contact with solid and liquid wastes

Emission/spillage etc. from storage &

handling – without any fire


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2 Level – II Onsite

Emergency Plan

Major Fire due to: Spillages from tank truck due to over

flow while loading

Spillages from storage tank during

receipt.

Floating roof getting struck in the

tank. Tank containment failure.

Leakage from pipeline due to damage

by external sources, sabotage,

pilferage

Failures caused by corrosion defects,

Failures caused by miscellaneous

factors such as pipe material defects,

natural hazards

Failure of mechanical structure

Failure of civil structure

Deposition of toxic pollutants in

vegetation / other sinks and possible

sudden releases due to accidental

occurrences

3 Level – III (Disaster)

Offsite Emergency Plan

Burst of product Pipelines inside

& outside premises.

Failure of storage tanks.

Pool Fires

Vapour cloud explosion.

Agitation / forced entry by external


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group of people.

Natural Perils – Earthquake, Flood,

Tsunami Sabotage, Bomb Explosion /

Threat.

Exposure to pollutants released from offsite/ storage/related activities

Contamination due to accidental releases or normal release in combination with natural hazard

Further, Hazard analysis involves the identification and quantification of the various hazards (unsafe condition) that exist in the plant. On the other hand, risk analysis deals with the identification and quantification of the risk, the plant equipment and Personnel are exposed to, due to accidents resulting from the hazards present in the plant. Risk analysis involves the identification and assessment of risks to the population exposed to hazards present. This requires an assessment of failure probability, credible accident scenario, vulnerability of population etc. Much of this information is difficult to get or generate consequently, the risk analysis in present case is confined to maximum credible accident studies and safety and risk aspect related to proposed Grain based Distillery and power plant. Activities requiring assessment of risk due to occurrence of most probable instances of hazard and accident are both onsite and off-site. Consequences of default or non-compliance There shall be a system for ensuring compliance to the provision of these regulations through developing a well-defined ONSITE EMERGENCY PLAN (OEP) and conduction of mock drill and safety audits during the construction, commissioning and operation phase, as well as on an on-going basis. There shall also be a system of do‟s and don‟ts regarding safety, mock drills or real

emergencies for the visitors before entering an establishment. This should be supported by written instruction sheet for the visitor and ensured that visitor is accompanied by plant representative on forward visit and return gate.

1) The Board shall monitor the compliance of ONSITE EMERGENCY PLAN (OEP), Technical Standards and Specifications including Safety Standards either


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directly or indirectly by accredited third party through separate regulations on third party conformity assessment.

2) In case of any deviation or shortfall, in achieving the recommended standards the entities are liable to penal provisions under the provisions of the technical standards, specifications including safety standards.

DIFFERENT EMERGENCY SCENARIOS- Onsite / Offsite Emergency

Emergency Scenarios Threats

Medical Serious injuries / Fatality or illness Heart Attack/ Health related Issues

Operational

Fire & Explosion Structural failure Pipeline leak or rupture Sabotage

Natural Disasters

Flood Cyclone Earthquake

Environmental

Chemical /Lube Oil/ Hydrocarbon Product spill Volatile Vapour cloud release

Security

Bomb threat Sabotage Kidnap and Ransom

Natural Peril – Earthquake & Flooding A flood possibility cannot be ruled out. Though floods are not likely to cause any direct damage to distillery facilities or associated equipment, it may however cause power/cable failures. Emergency shutdown system should be in place to tackle such situations. Plant lies in Zone -3 of Earthquake zone. Sabotage / Bomb Threat In case of any sabotage, the worst expected consequence would be a large release of flammable hydrocarbons and/or fire involving property damage or harm to human. Bomb threats could be real as well as hoax. However, all bomb threats should be taken seriously. Details of the conversation should be immediately furnished to the incident controller, who should in turn contact the local police as well as the district collector. The employees and contractors shall be given training to prevent entry of


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unauthorized persons / material and sharing information on actual incidents of sabotage/ terrorist activity.

PROBABLE CAUSES OF EMERGENCIES The common causes for the above events are tabulated below for reference and the ONSITE EMERGENCY PLAN (OEP) should be prepared by the installation to deal with the following emergencies.

Man made Natural Calamities Extraneous

Heavy Leakage Fire Explosion Failure of Critical

Control system Design deficiency Unsafe acts In-adequate

maintenance

Flood Earth Quake Cyclone Outbreak of Disease Excessive Rains Tsunami

Riots/Civil Disorder/ Mob Attack

Terrorism Sabotage Bomb Threat War / Hit by missiles Abduction Food Poisoning/

Water Poisoning

HAZARDS AND SAFETY MEASURES FOR STORAGE & HANDLING OF ALCOHOL : Physical Properties: Chemical Formula : C2H5OH Molecular Weight : 456. Sp. Gravity : 0.7147 Highly volatile, colourless, bitter in taste, surest smell, and highly inflammable liquid. It is mixable in all proportions with water, eathers and other alcohol. Its flash point is as low as 400 C and can catch fire at elevated temperature. It forms explosive mixture with air, if mixed to the extent of 2.6% by weight. It has no severe effect on skin or tissues if inhaled. It has fire hazard. Possible measures have to be taken for arresting the same in time. Step has been taken to install sprinkler system on and around the storage tanks.


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The alcohol will be directly fed to the bottling unit mechanically and no manual handling will be involved which will reduce the risk of spillage in the storage area. Following precautionary measures would be taken for safety: Handling And Storage: Keeping away from heat, sparks and open flame, care will be taken for

avoidance of spillage, skin and eye contact, well ventilation, Use of approved respirator if air contamination is above acceptable level will be promoted.

Keeping away from oxidizers, heat and flames. Avoidance of plastics, rubber and coatings in the storage area. Cool, dry, & ventilated storage and closed containers. Grounding of the container and transferring of equipment to eliminate static

electric sparks.

In case of any emergency following measures would be taken: • FIRST AID MEASURES: For Skin contact, Eye contact, & Inhalation. • FIRE FIGHTING MEASURES: Use of extinguishing media surrounding the fire as water, dry chemicals (BC or ABC powder), CO, Sand, dolomite, etc Foam System for firefighting will be provided to control fire from the alcohol storage tank. The foam thus produced will suppress fire by separating the fuel from the air (oxygen), and hence avoiding the fire & explosion to occur in the tank. Foam would blanket the fuel surface smothering the fire. The fuel will also be cooled by the water content of the foam. The foam blanket suppresses the release of flammable vapors that can mix with the air. Special Fire Fighting Procedures; Keeping the fire upwind. Shutting down of all possible sources of ignition, keeping of run-off water out of sewers and water sources. Avoidance of water in straight hose stream which will scatter and spread fire. Use of spray or fog nozzles will be promoted, cool containers will be exposed to flames with water from the side until well after the fire is out. Hazardous Decomposition Products: gases of Carbon Monoxide (CO) & Carbon Dioxide (CO2). •ACCIDENTAL RELEASE MEASURES: For Spill Cleanup well Ventilation,

Shutting off or removal of all possible sources of ignition, absorbance of small quantities with paper towels and evaporate in safe place like fume hood and burning of these towels in a safe manner), Use of respiratory and/or liquid-contact protection by the Clean-up personnel will be promoted.


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ELECTRICAL HAZARDS: Though, flame, proof fittings are provided Electrical injuries may occur any where. It may be caused by direct current, alternative current or from lightening. The security of the injuries by electric shock depends upon : 1. The amount of current flowing through the body. 2. The path of current has taken through body to the earth. A weaker current passing through the chest is more dangerous than a relatively stronger current passing through the lower limits. 3. Length of the victim is in contact. 4. Type of electric energy AC or DC. 5. Physical condition of victim. Following signs and symptoms are found in electric shocks: 1. Sudden spasm 2. May be unable to release hands which holds the live point. 3. Burns 4. Cries aloud and falls on the grounds. 5. Several pain. 6. Unconsciousness. 7. Breathing impaired or stopped. 8. Burns leading to severe surgical shocks. FIRST AID / COUTNER MEASURING Any delay in first aid in electric shock is a delay for ever, hence the person Giving the first aid must not get excited and must not endanger his life. 1. The current must be cut off or the plug should be pulled out. 2. He must not touch the victim or the live conductor. 3. If it is difficult to cut the current, the victim has to be separated by using a dry coat rope, stick etc. 4. If there is the dry wooden chair or rubber sheet, he must stand on it and then separate the victim. 5. If the cloths are smoldering, the spark should be extinguished. 6. Artificial respiration is to be started immediately. This may be done whenever the victim is in unconsciousness while the pulses. The artificial respiration should be continued till the doctor has arrived one may like to continue for atleast 8 hours before obarconing the case as dead.


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When the patient start swallowing, one may understand that spontaneous breathing is being received. Artificial respiration should be continued till normal movement of breathing is fully established as the respiration may falls again if left earlier. 7. A blanket should be out around the patient. The patient has be kept warm to treat the shock. He may be given warm, sourest drink if he is conscious otherwise not, as it may harm him. 8. Superficial bones of lightening strange may be covered with a septic dressing. The deeper bums caused from contact with live conductors may be covered with clean sheet and the patient taken to a hospital without any further delay. 9. External cardiac massage may be given if the pulse is not felt or even artificial respiration. Power Cables It is to be secured properly. It is to be protected from physical hazards. All junction boxes should be protected and supported. Checking of ear things is necessary. All junction box should be filled with compound.


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10. EMERGENCY MITIGATION & PREPAREDNESS After determining the risk level, the following actions shall be required for mitigation of emergency: -

a. Basic requirement of ONSITE EMERGENCY PLAN (OEP)

Basic requirement needs to be assessed prior to development of OEP as per the requirements to handle Level-I and Level-II emergency.

b. Resource mobilization

Resource mobilization shall include manpower requirement, firefighting materials, appliances or equipment, safety equipment, communication facilities, transport, list of emergency drugs and appliances, etc. as given in Annexures.

c. Incident preventing measures and procedures.

The incident prevention measures and procedures at installation or other locations shall include the following:-

a) health safety and environment (HSE) policy; b) proper layout and inter facility distances (the layout should not have any

crisscross movement of men and materials); c) safety committees with fair participation of Union leaders and workers; d) safety audits and inspections shall be carried out with the help of prescribed

checklists. e) work permit system (including confined space and entry permit); f) early warning alarm system in the installation (gas monitoring system, heat

detection, high level alarms, low pressure/high pressure alarms etc.) especially in the vicinity of storage tanks, filling station, delivery points and along with periphery with the indication in the central control room;

g) in-built safety interlocks system in design such as safety relief valves (SRVs), thermal safety valves (TSVs), non-returning valves (NRVs), remote operated valves (ROVs) and other various emergency trip systems in Installations;

h) fire protection (preferably automatic) and HSE Management system; i) drill for visitors including assembly procedure and escape route, do‟s and

don‟ts written instructions before entry, etc.; j) setting up of safety MIS system and sending Exception reports to the head of

organizations or CEO; k) all standby equipment‟s should be tried and operated periodically and

recorded. Similarly back up power for safety equipment and instrument should be checked periodically and observations be recorded;

l) check points for incident prevention measures are also given in Chapter on Incident Prevention Measures.


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d. Emergency Drills and Mock Exercises

(a) To evaluate the thoroughness and effectiveness of an OEP, it is necessary to conduct periodic table top exercises full-scale or announced, and unannounced drills. Each site should hold drills on the night shifts, change shifts as well as during the day.

(b) Drills should present a variety of Emergency scenarios and designed to challenge each segment of the organization. Limited scale drills are useful and should be used by Chief of each Support Service to train his own team. Plans should be made to have periodic mass casualty exercises. These exercises should attempt to simulate as closely as possible a fire, explosion, or toxic agent release and comparison of the prescribed time lines and the actual received.

(c) The warning system, first aid, evacuation procedures and the definitive treatment procedures should all be tested periodically.

(d) Some of the drills should also include the participation of outside groups and agencies such as police, fire companies, ambulance service, civil defence organizations and mutual aid groups.

(e) Testing and mock drills for onsite emergency plan shall be carried once in three months and for offsite emergency plan twelve months.

(f) For other installations, the mock drill shall be carried out once a year. However, for locations having more than one industry member, the annual mock drill can be carried out by one industry member in turn, thus ensuring one mock drill in every year at the location.

(g) These mock drills will enable the unit/location to assess the capability of the individual and performance as a group. The frequent discussions and drills will help in eliminating the confusion and shortcomings, if any.

(h) Each Mock Drill should be recorded with observations and deficiencies to be rectified within 24 hours.

e. Training

An OEP shall be easier to use if training material and general philosophy on emergency prevention and control are kept separate from the working plan. (a) Training shall be imparted to all the personnel likely to be involved directly or

indirectly to the emergencies including employees, contract workers, transport crew and security personnel.

(b) Contract personnel and contract laborer shall be allowed to start work only after clearance of attending and passing safety training.

(c) Refresher training shall be conducted at regular intervals. (d) The basic requirements of Central Motor Vehicles Rules, 1989 pertaining to

dangerous or hazardous goods transport must be complied by the transporters and for this the loading section must conduct training of tank truck crew.


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11. EMERGENCY RESPONSE PROCEDURES AND MEASURES Containing the consequences of an emergency requires well planned and documented procedures to ensure prompt response and coordination among various task groups. The following response procedures as prevalent in the location shall be carried out:

a. Zoning and Maps.

This document can be referred to identify different Risk zones on the layout based on the Risk level experienced from all hazards in the facility

a) The zones and maps shall be prepared highlighting the Incident prone areas of the unit so that in case of an emergency it serves as a basis for taking the action. This indicates the size of the area within which human life is seriously endangered by the consequences of incident. This should also indicate the location of assembly points and emergency control rooms. The map should also have marked 24 wind directions to facilitate easy access in case of emergencies.

b) The entities shall help District Disaster Management Authority (DDMA) in finalizing the full drawn map of installations and nearby areas under their operations having presence of habitats which are vulnerable and sensitive like old age homes, schools, prison, etc.

c) Wind speed and direction should be recorded with the help of anemometer and declaration of off-site emergencies should be immediately communicated to DDMA.

b. Layout/flow diagram -

Detailed layout and flow diagram for different activities such as Product Lines, filling system, emergency shutdown system isolation valves etc. should be detailed. The important control valves should be highlighted.

c. Manpower data

All the staff at the installation is trained in firefighting and all new staff is given charge after undergoing extensive firefighting training. In addition, trained staffs are given refresher training courses periodically. The details (designation) and duties of the staff are given below in the “Fire Organization Chart”.


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Name of the Personnel Designation Role assigned in FOC Sh. Dalbir Singh AGM Chief Incident Controller/Site

Incident Controller Capt. Lakhwinder Singh Head-Combat

Team Leader of Emergency Combat Team:-To terminate the TLF Operations, reach the place of incident with nearest available firefighting equipment, start firefighting with water & foam mixture.

Mr. Satinder Singh

Asst. Manager- HR

Leader of Rescue Team:-To call various important outside agencies, to communicate important information to control room and to be in touch with Chief Incident Controller/Site Incident Controller.

Mr. S K Srivastava Manager Utility

Leader of Auxillary Team:-To reach the place of fire/incident and to provide all possible help to Emergency Combat Team according to situation.

Mr. Vikram Singh Bedi Manager Mechanical

Member of Auxillary Team:-To reach the place of fire/incident and to provide all possible help to Emergency Combat Team according to situation.

Mr. Sanjiv HR Executive Member of Rescue Team:-To call various important outside agencies, to communicate important information to control room and to be in touch with Chief Incident Controller/Site Incident Controller.

d. Emergency Control Organization and Responsibilities

Overall objectives of an emergency control organization shall be: a. to promptly control problems as they develop at the scene. b. to prevent or limit the impact on other areas and off-site. c. to provide emergency personnel, selecting them for duties compatible with

their normal work functions wherever feasible. The duties and functions assigned to various people shall include making full use of existing


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organizations and service groups such as fire, safety, occupational health, medical, transportation, personnel, maintenance, and security.

d. Employees must assume additional responsibilities as per laid down procedure of ONSITE EMERGENCY PLAN (OEP) whenever an emergency alarm sounds.

e. In setting up the organization, the need for round-the-clock coverage shall be essential. Shift personnel must be prepared to take charge of the emergency control functions or emergency shutdown of system, if need be, until responsible personnel arrive at the site of emergency. The organization should have an alternate arrangement for each function.

e. Organization chart.

Medical Services and Ambulance

Fire Brigade Services

Police Services

Off-Site Incident Commander

(District Magistrate)





CHIEF INCIDENT

CONTROLLER



Affected Stake Holders and Government Authorities

SITE INCIDENT

CONTROLLER

Mutual Aid

Municipal transport rescue and

rehabilitation team

Fire Safety and Fire Team /HSE

Coordinator

Administration and Communication

Coordinator

Operation Team, technical team,

etc.

Support Services *

Level – I Level II Level III ---------


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Note:* (1) Above is a typical and basic organogram for control of emergency. Entity can

merge the functions as per their other statutory requirements and based on level of risk and range of operations. The organization shall have to address all services and support system required and available to it.

(2) Support Services Include Communication Services, Engineering/Maintenance Services, Medical and Occupational Health, Human Resource and Welfare Service, Security, Media/Public Relations, Transport and Logistics, Finance, Contract and Procurement and Environmental Services.

(3) Role of both CIC and SIC can be merged depending upon the requirement.


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12. ROLES AND RESPONSIBILITIES

Chief Incident Controller.

The Chief Incident Controller (CIC) is the facility manager in facilities. He shall have overall responsibility to protect personnel, site facilities, and the public before, during, and after an emergency or disaster. The CIC shall be present at the main emergency control center for counsel and overall guidance. Responsibilities of the Chief Incident Controller shall include the following: - a) preparation, review and updation of the ONSITE EMERGENCY PLAN (OEP)

as per Check List-5; b) assessment of situation and declaration of emergency; c) mobilization of main coordinators and key personnel; d) activation Emergency Control Centre; e) taking decision on seeking assistance from mutual aid members and external

agencies like Police, Fire Brigade, Hospitals etc.; f) continuous review of situation and decide on appropriate response strategy; g) taking stock of casualties and ensure timely medical attention; h) ensuring correct accounting and position of personnel after the emergency; i) ordering evacuation of personnel as and when necessary; j) taking decision in consultation with District Authorities when an Off-site

emergency to be declared.

Fire Chief

a) To reach the site and take charge b) Access the gravity of the situation and activate emergency response plan c) Co-ordinate with Team in-charge of the fire fighting d) Ensure visitors, contractors and labors safely assemble at designated place e) Ensure safe evacuation of people /TTs/ properties f) Seek help of local administration, members of mutual aid and reporting office g) Reassess the emergency and if the situation goes out of control, activate off site

emergency plan in coordination with district authorities

Site Incident Controller (SIC)

The Site Incident Controller shall be identified by the Chief Incident Controller and will report directly to him. SIC should be nominated by the entity in each shift 24 hrs. Responsibilities of the Chief Incident Controller shall include the following: -


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a) The SIC shall maintain a workable emergency control plan, establish emergency control centers, organize and equip the organization with ONSITE EMERGENCY PLAN (OEP) and train the personnel;

b) The SIC shall be capable of making quick decisions and taking full charge; c) The SIC shall communicate to the Emergency Control Centre where it can

coordinate activities among groups; d) The SIC shall be responsible for ensuring that appropriate local and national

government authorities are notified, preparation of media statements, obtaining approval from the CIC and releasing such statements once approval received;

e) The SIC shall also ensure the response to the incidents or the emergencies, as the case may be, is in line with entity procedures, coordinating business continuity or recovery plan from the incident. He must ensure next of kin are notified in a timely manner;

f) The SIC shall also co-ordinate if any specialist support is required for the above purpose; and

g) The SIC shall decide on seeking assistance of mutual aid members and external agencies like police, fire brigade, hospital etc.

Administration and Communication Coordinator

Responsibilities of the administration and communication controller shall include the following: - a) to coordinate with mutual aid members and other external agencies; b) to direct them on arrival of external agencies to respective coordinators at

desired locations. c) to activate the medical center and render first aid to the injured. arrange

ambulance and coordination with hospitals for prompt medical attention to casualties;

d) to ensure head counts at assembly points; e) to arrange procurement of spares for firefighting and additional medicines and

drugs; f) to mobilize transport to various teams for facilitating the response measures; g) to monitor entry and exit of personnel into and out of premises; h) to ensure only authorized personnel enter into the premises; i) To regulate the flow of traffic into and out of premises and control the mob

outside, if any, with the assistance of the police. j) to provide administrative and logistics assistance to various teams; and


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k) to arrange evacuation as directed by the chief incident controller, and in coordination with the civil authorities like police, panchayat/municipal authorities etc.

Fire Safety Coordinator and Fire Team.

Responsibilities of the Fire and Safety Coordinator shall include the following: - a) to activate emergency sirens as per the practiced codes; b) to take charge of all firefighting and rescue operations and safety matters; c) to ensure that key personnel are called in and to release crew of firefighting

operations as per emergency procedure; d) assess functioning of his team and communicate with the CIC and or

administrative controller for any replenishment or, replacement of manpower or firefighting equipment;

e) direct the fire brigade personnel and mutual aid members to their desired roles as also proper positioning of the manpower and equipment;

f) to decide the requirement of mutual aid and instruct fire station, who, in turn will contact mutual aid members;

g) to coordinate with outside fire brigades for properly coordinated firefighting operation;

h) to ensure that casualties are promptly sent to first aid center / hospital; i) to arrange requirement of additional firefighting resources including help from

mutual aid partners; j) ensure empty and loaded trucks are removed to safer area to the extent possible

so as not to affect emergency handling operations; k) continually liaise with the SIC and or CIC and implement the emergency

combat strategies as communicated by him; and l) ensure adequate hydrant pressure in the mains and monitor water level in the

reservoir. Note: Fire chief shall wear identification jackets at the site of disaster so that he is clearly distinguished among firefighting personnel and is visible from a distance.

Additional Teams

1. Fire/Emergency Combat Team On hearing the sound and seeing the indicator available near the gate barrier, rush

to the spot of fire/ emergency or follow red flag carried by security guard. Rush to the site & start extinguishing fire with fire extinguishers at the initial

stage when fire is small.


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Start using water from nearby hydrant/ monitor/ foam as the case may be till fire is extinguished as per wind direction.

Receive instructions from fire chief & coordinate for operation of firefighting equipment‟s.

In case of other emergency like leakage of product, arrest the source while it is being diluted with fine water spray.

Keep on updating information to fire chief & suggest for necessary assistance if required.

After getting clearance from fire chief & hearing clear siren, assemble at assembly point.

2. Auxiliary team Rush to the site & report to fire chief. Coordinate with fire combat & rescue team in charges for replenishment. Collect fire extinguishers, nozzles, foam nozzles, foam cans & make them ready

to supply all these to fire combat team members at the spot of fire. Keep on updating information to fire chief.

3. Rescue team Reach at the site & report to fire chief. To coordinate for PPES/ evacuation/ first aid/stretcher/ rescue operations. To identify casualty & give first aid. Keep on updating information to fire chief. Give head count to fire chief. To safe guard documents, records & other important files. To communicate with mutual aid members, district administration, police, fire

brigade & other external agencies & controlling office. Arrange drinking water & food. Communicate with public arriving at gate.

Security Coordinator

The Security Coordinator reports to the Chief / Site Incident Controller and is responsible for security of the installation during any incident or emergency situation and for implementing the actions below: a) Obtaining an approved visitor list from the security department or reception for

ensuring that personnel on the list are escorted to reception by security staff;


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b) Maintaining security of the office in the event of an office evacuation; c) Providing office security and assisting authorities in the event of civil unrest or

when required organizing additional security at the emergency scene; d) Obtaining initial briefing from Chief / Site Incident Controller and providing

security information and or status reports to Site Incident Controller during the emergency;

e) Assuming responsibility for any task delegated by Chief Incident Controller; and

f) Assessing the emergency, identify security specific problems and recommend solutions to Chief Incident Controller.

Head of HSE or any other designated personnel

Maintenance of ONSITE EMERGENCY PLAN (OEP) Records

There shall be maintenance of ONSITE EMERGENCY PLAN (OEP) records for all kind of emergencies covering near Miss, Level-I, Level-II and Level-III. Organization shall maintain an Incident Record Register for the above purpose and post–disaster documentation like resources deployed, relief, rehabilitation measures and lesson learned to avoid re-occurrence of any such emergency. Head of HSE or any other designated personnel by the CIC/SIC shall be responsible for maintenance of such records.

1) A good public relations program is extremely important in an emergency situation. Inquiries will normally be received from the media, government agencies, local organizations and the general public.

2) This section of the Response Plan shall include a public relations or media plan. It should identify an Information Officer that is well-equipped and trained in media relations.

3) Initial releases shall be restricted to statements of facts such as the name of the installation involved, type and quantity of spill, time of spill, and countermeasure actions being taken. All facts must be stated clearly and consistently to everyone.

Note- Plans shall also be developed to utilize local media and television stations for periodic announcements during an emergency. This shall also assist in reducing rumors and speculation.


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Recorder The Recorder responsibility is to maintain an accurate time record of key information received from the incident or emergency location and to record the actions initiated by the site incident controller and for implementing the emergency response actions below:

a) to record key incident events/actions on incident status board/display manually or electronically;

b) to maintain essential equipment checklist status; c) to ensure all status and information is up to date and correctly displayed; d) to take all necessary recorded material to the alternate ECC room in the event

of emergency in main ECC room; and e) to maintain a log book.

Roles and responsibilities of stakeholders including external agencies

Role and responsibilities of stakeholders including external agencies such as District Authority, police, fire service, revenue department, health department, pollution control board, National Disaster Response Force (NDRF) and State Disaster Response Force (SDRF). For roles and responsibilities of above stakeholders and responders, primarily district collector as Head of emergency operation and other authorities under his charge including external agencies, has been defined in Schedule–V. These roles and responsibilities are generally in line with National Disaster Management Guidelines on Chemical Disasters, April, 2007, brought out by National Disaster Management Authority.


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13. FIRE PROTECTION SYSTEM & SOPs

i. Classification of Fire

A small spark of fire may result into loss of machines and the damage by fire may

high economic losses. This type of losses can be avoided by preventing and

controlling the fire instantly for which fire–fighting group will be established.

Different classes of fire are explained as follow:

Class (A)-Fire involving combustible materials like wood, paper, cloth etc.

Class (B) -Fire due to liquid materials like oil, diesel, petroleum products and all inflammables.

Class (C) -Fires involving domestic and industrial gases like butane and propane etc.

Class (D) -Metal fires etc.

Class (E) -Electrical fires due to short circuiting etc.

ii. Recommendations to be followed to avoid fire:

Any other flammable materials in the installation shall be stored in a non-flammable chamber with a minimum safety distance of 15 M from compressor station/ electrical installation. All approaches to machines, compressors, storage facilities and work places shall be free from obstacles, so that they are readily accessible in an emergency. The electrical installations shall be inspected by a competent Electrical Inspector as per IE Rules and compliance shall be made as pointed out in the inspection. Records shall be maintained for all periodic inspections. The flameproof characteristics of electrical equipment shall be checked through visual checks, condition of gasket, completeness and tightness of bolts, glands and as recommended by manufacturer's product catalogues /test certificates. No unauthorized additions or modifications, whether temporary or permanent, shall be taken up. Proper illumination to be ensured for all operating and non-operating areas. All electrical maintenance at the Automotive Station shall be undertaken by licensed electrical technician under supervision of authorized person. Each installation shall have minimum two numbers hand held explosive meter in working conditions and two self-contained breathing apparatus(SCBA) at all times.


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Establish which would house and keep in readiness, the following types of equipment and arrangements. CO2 extinguishers, Dry powder chemical extinguisher, Foam extinguishers ,80 mm. spray hoses ,Fire brigade,Fire hydrant, Protocol (chemical to combat oil fires). In order to avoid fire in cable galleries, all the power and control cables of FRLS type (Fire Resistant Low Smoke) will be used. Firefighting facilities need to be carefully planned after considering the availability of municipal fire tenders etc. Survey shall be conducted at set frequency to establish the requirements related to fire suppression system and equipment‟s, with reference

to mandatory regulations and organization‟s requirements; objectives shall be set to

comply to the requirements/guidelines iii. SOP for Fire Water Tanks

a) In case of any shortage of water in tanks arrange for replenishment of water b) All hydrant valves must be fully closed. The bypass valve from hydrant to

storage tanks must be in closed condition c) Ensure fire water is not used for any other purpose. No tap off to be taken

from hydrant for this purpose to feed other system d) Location may find the possibility of water harvesting where there is acute

shortage of water e) Ensure double earthing of fire water storage tanks

iv. SOP for Hydrant System

a) Ensure isolation valves near loop junction b) Ensure isolation valve, kept closed due to repair, is tagged conspicuously and

reopened immediately after repair without fail c) Ensure installation of strainers before the butter fly/ other valves to prevent

chocking of valves seat for internally coated pipeline d) Ensure that hydrants and monitors are not installed inside the dyke areas or at

any inaccessible area e) Ensure no valve is closed on the hydrant line for sprinkler of the tanks, pump

house and gantry

v. SOP for Dry Chemical Powder fire extinguishing system

a) Ensure safety clip of all extinguishers b) Ensure safety pin on the CO2 cartridge of trolley mounted extinguishers c) Ensure that extinguishers are placed on hanger at easily accessible position


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d) Ensure stand, painted fire red with rain protection cover for extinguishers placed in open

e) Ensure that no extinguisher is placed on the ground f) Ensure max. running distance to locate extinguisher does not exceed 15m g) Ensure that top surface of installed extinguisher is not more than 15 m above

the floor/ground level h) Ensure minimum 10% of the total refills in the extinguisher is maintained at

the location i) Ensure that extinguishers are painted whatever required and bottom of the

extinguisher are always in good condition j) Ensure that any extinguisher failing in hydro test is condemned k) Ensure that hydro testing of fire extinguisher is carried out once in five year

vi. SOP for Fire Detection & communication System

In case of emergency, nearest MPC to be operated, this will indicate an alarm in the fire alarm panel present in the control room and repeat panel in the security cabin

Ensure that:

a) Security has access to direct telephone after office hours b) Availability of emergency telephone numbers list in security cabin and other

important places c) That the handle of hand operated sirens are attached to the sirens.

vii. Safety Instructions to be followed at the time of fire

a. Do’s

Attend to the casualty as quick as possible. Get through history of the accident. Make the casualty self-comfortable while giving first aid. Uncover the casualty as little as possible. For fracture: Whenever possible use splint to restrict movement. The fracture

can be recognized by - excruciating pain, swelling, and loss of muscle power, deformity and unnatural movements.

Transport a lower jaw fracture casualty with the face downward position or sitting position.

In case of fracture of collarbone, upper limb – use triangular bandage to support as slings, triangular slings to prevent pull by upper limbs to injuries to chest, shoulder and neck.


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In case of fracture of hand, the forearm is bandaged by use of the simple spiral in the lower half and reverse spiral for the upper half.

A casualty with the fracture of the spine, pelvis, kneecap, leg must be lifted with a blanket list or the emergency method.

In case of external wounds stop bleeding initially by pressing gently the wound site & elevating arm or leg if there is no fracture, rest and continue to keep still until clot forms. Clean the wound with antiseptic. Put a sterile dressing, fix with bandage or clean cloth and take the casualty to a doctor.

In case of internal wounds like lings, stomach, kidney – rest the casualty and ask him to keep still and take them to a hospital as quickly as possible.

Treat for shock if casualty feels faint or giddy, vomits. Put the casualty comfortably on his back, loose tight clothing, but do not remove clothing and admit to a hospital on top priority.If there is no chest or abdominal injury and the patient is conscious, give sips of water, hot tea or coffee or tender coconut water and admit to a hospital on top priority.

In case of Asphyxia (suffocation), make air passages clear and give artificial respiration for want of oxygen in the circulating blood.The artificial respiration is given after placing the casualty face upwards on hard surface and mouth to mouth method, external heart compression – with arms straight, rock forwards pressing down on the lower half of breast bone at a pressure of 60 to 80 times per minute.

In case of snakebite, apply a constructive bandage on the heart side tight enough to obstruct and stop flow of venom to all parts of the body.

Constructive bandage should be released once in 20 minutes for at least 2 to 3 minutes.

Wash the wound with soap and water. Flush with lot of water and cover the wound with sterile dressing. Get medical aid or send person on stretcher to the hospital as quickly as possible.

In case of dog bite, wipe the saliva away from the wound. Wash the wound thoroughly with plenty of soap and water, cover the wound with a dry, sterile dressing and send the patient to the hospital for treatment of wound and also to protect from rabies and other infections.

In case of burns, do not remove the clothing unnecessarily. Immerse the burnt part in the cold water for 10 minutes. Do not use any ointment. Dress the wound with clean materials. Do not open the blisters. Sips of water or tender coconut can be frequently given. Transport to hospital.

In case of epilepsy, the casualty may lose consciousness for few seconds. Do not stop convulsions; remove objects that may cause injuries. Wipe froth


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from the mouth. After regaining consciousness, accompany casualty to a doctor.

In case of foreign body in the eye, avoid rubbing the eyes. Instruct to blink the eyelids in a cup full of water. If not successful, make a pointer with the corner of a clean handkerchief moisten it and try to remove the foreign body with it. If acids, quick lime gets into the eye, flush the eye with plenty of water, dress the eye, and send him to a doctor.

b. Don’ts

Do not try to set right a dislocated joint. Avoid movement of part if fracture occurs as far as possible. Do not use spirit near the eye or an open wound. Do not apply bandages too tight so as to impede circulation. Do not neglect a dog or monkey bite. Do not induce vomiting where a casualty is unconscious. Do not give a key bunch or an iron article in the hands of a casualty. Do not administer oil to casualty of Rat poisoning. Do not administer salt solution for vomiting to a casualty in case of

poisoning. Do not attempt to do too much and take the responsibilities of qualified

doctor. Do not feed a casualty when you suspect an internal injury or when he is

unconscious having fits. Do not waste much time in a condition of internal bleeding or head injury but

transport the casualty as quickly as possible to a hospital. Do not apply oil or ink on burns and scalds. With a snake bite casualty is reported do not waste time in using, “Mantras,

Tantras and Pooja” but transport him to a hospital immediately as possible.

viii. viii. Resources for controlling Emergency

To meet all possible emergencies, installation has to provide a number of systems and resources based on the risk level as identified above in addition to requirements under the Factories Act, 1948 and other statutory regulations applicable to the installation.

The available emergency control systems and facilities within the installation shall be as under: -

a) fire and gas detection system


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b) fire protection system (Active and Passive) c) firefighting systems d) ambulance facility in house, if not available then should be available on

urgent call basis. e) rescue facilities and personal protective equipment (PPEs) f) first aid and medical facilities round the clock with availability of minimum

one nurse (24X7) and doctor in the first aid room. g) communication facilities h) escape route and evacuation zones i) emergency shutdown system

Required resources shall be suitably incorporated into the plan. Number and type shall be as per the relevant code, standards and best practices in the industry. This section shall also identify sources of local assistance including telephone numbers and names of contacts for:

a) fire departments b) police c) municipal and provincial agencies d) hospitals e) doctors f) other relevant company facilities g) mutual aid organizations h) co-operatives i) surface transport services j) safety and monitoring equipment suppliers k) spill response and/or cleanup services

Installations shall also determine type of resources such as equipment, personnel, technology, expertise, etc. provided by the respective governments under different conditions. ix. Record Regarding Mock Drills

Sr. No. Check-point 1 Whether mock fire / emergency response drills are held 2 If yes, periodicity of emergency response drills 3 Mock drills cover all types of probable emergencies 4 If yes, the details of other members including names and contact nos. of


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concerned officials 5 List of fire fighting equipments available 6 Compatibility of safety equipment including District Fire Services with

said location has been tested and documented in the DMP 7 Details of water storage available including District Fire Service and

mechanism to utilize the same in the said location well documented in the DMP

8 Details of firefighting foams concentrate/chemicals available including nearest Fire Service has been incorporated

9 Details of lead time for response of District Fire Service has been documented in the DMP

10 Periodicity of safety training for officers, staff, contractor workers, TT crew and security personnel mentioned in the ONSITE EMERGENCY PLAN (OEP).


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14. COMMUNICATIONS SERVICES & INFRASTRUCTURE

The Communications Coordinator shall ensure the following actions below: a) Ensuring the ECC equipment and systems are maintained to a high standard and

remain functional throughout the emergency. b) Ensuring a back-up communication system is available in the event of the ECC

Room is not available. c) Providing quality and diverse communication systems for use in routine and

emergency situations. d) CONTROL ROOM - Communication Facilities in M/s Malbros are Intercom

Telephone, P&T Telecom, Wireless (Mobile) Communication System.

i. Communication Flow Chart

Note: 1. above is a typical communication flow chart for notification of emergency. 2. Wherever communication exists for any level of emergency, it automatically

implies that the communication exists for all higher levels of emergencies.

EMERGENCY CONTROL CENTRE

(ECC)

SITE INCIDENT CONTROLLER

MANAGEMENT TEAM

(Head Operations, Head Maintenance, Head

Technical, Head HSE, Head Security, Head

(HR)

Employee/ Security

Fire safety/HSE Coordinator and

fire team

CRISIS MGMT GROUP

Mutual Aid Members

Info. to Fire Brigade, Police,

Medical and Government Authorities

First Responder

Fire and gas detection

system/ SCADA System

Police

Public

District Administration

and Central Govt. agencies

CHIEF INCIDENT CONTROLLER

Note: Level I Level II

Level III

Others (required coordinators of the

installation)


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ii. Flow of Information

a) Control Centre shall receive the information form field either in person or from the various systems available in the installation.

b) on receipt of information, the control room shift In-charge will actuate the ONSITE EMERGENCY PLAN (OEP) and notify the emergency to site incident controller.

c) Control room shift in-charge will act as site incident controller till arrival of designated person.

d) SIC or CIC depending upon the level of emergency will actuate the ONSITE EMERGENCY PLAN (OEP) and inform the concerned authorities as depicted above in the chart.

Note: Apart from the above main function, the role and responsibility of other support services such as finance, material etc. should also be detailed.

iii. Siren Codes

1) The Emergency siren/s should be located suitably to cover the whole area with the operational control within the installation. These should be tested at least once in a week to keep them in working condition.

2) Emergency siren code should be as follows, namely: - a. Emergency Level-I: A wailing siren for two minutes. b. Emergency Level-II and III: Same type of siren as in case of Level – I and II but

the same will be sounded for three times at the interval of one minutes i.e.(wailing siren 2min + gap 1 min + wailing siren 2min + gap 1min + wailing siren 2min) total duration of Disaster siren to be eight minutes.

c. ALL CLEAR: Straight run siren for two minutes. d. TEST: Straight run siren for two minutes at frequency at least once a week e. Public address system should be provided with message. 3) Codification of Sirens in M/s Malbros is as follow:

Sr. SIRENS INDICATES AUTHORITY

1. 30 SECOND ON SITE INCIDENT

CONTINUOUS EMERGENCY (ALERT) CONTROLLER

2. 1 MINUTE EMERGENCY SITE CONTROLLER

CONTINOUS CONTROLLED

(ALL CLEAR)

An alarm does more than just emergency warning. It also instructs people to carry

out specific assignments, such as reach to assembly point for further instructions


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and actions, or carry out protective measures; this can be achieved only if the

people are familiar with the alarm systems and are trained to respond to it.

iv. Details of the Emergency Control Centre (ECC)

Each installation shall have the provision of ECC preferably with a back- up arrangement.

a) The ECC shall be away from potential hazards and provide maximum safety to personnel and equipment.

b) Preference should be given to a non-combustible building of either steel frame or reinforced concrete construction.

c) The ECC should have at least two exits and adequate ventilation . To direct and coordinate the operations, the administrative/office building has been nominated and developed as the Emergency Control Center. In an emergency it is almost essential to evacuate affected person from inside the factory to a safer place. It is also essential to evacuate non-essential workers to streamline Emergency Action Plan activities and ensuring safety of those people. The evacuation will be effected after getting information from the Works Incident Controller soon after emergency arises. On evacuation all contract laborers, visitors etc. other than those notified as team member shall assemble at the assembly point for receiving further instructions. At the time of the emergency On-site Chief Controller assisted by other designated coordinators shall take position here to perform their duties. Its location is outside the area of potential hazards and is easily approachable. Both the Emergency Control Center have the following resources available at all times: 4 Copies of the On-site Emergency Plan. Layout Plan of the complex. Plans of work illustrating the following: Plan of chemical storage tanks with pipeline details Sources of safety equipment Fire Hydrant System Layout Stock of firefighting equipment Location of assembly points Location of works in relation to surrounding community A list of telephones of key and essential staff of the company along with their

addresses and residential numbers.


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Copies of the local Telephone Directories. A list of important telephones like neighboring industries, local Fire Brigade,

Hospitals, Chief Inspector of Factories. Personal Protective Equipment. First – Aid Kit. Communication equipment – Telephone Public Address System Requisite stationary items: notepads, pens and pencils. Facilities for recording the

sequence of events should be provided to assist in investigating causes, evaluating performance, and preparing reports. This can range from a pan board, logbook to a tape recorder with a person assigned to record pertinent information.

Personnel to act as messengers. Binoculars, Torches and explosive meters. ECC should also have dedicated computer with LAN/ internet facility to access the

installation data and also it should have the latest and updated soft copies of all standard operating practices (SOP) etc.

The communication equipment is checked periodically to ensure that they are functional. The Emergency Management Control Center is capable of being activated within a few minutes upon declaration of an emergency.

v. Assembly Point and Their Area Coordinator

Assembly Point -In an emergency, it will almost certainly be necessary to evacuate personnel from affected areas and, as a precautionary measure, to further evacuate nonessential personnel from areas likely to be affected should the emergency escalate. The evacuation will be effected on getting necessary message from Site Controller. On evacuation, employees should be directed to pre-determined safe place called Assembly Point.

Escape Routes -The roads leading to the Assembly Points are the designated escape routes. The escape routes will be clearly marked with arrow marks for easy escape.

The Assembly point of the location is Near Entry Gate. As soon as the non-essential contract laborers come to know of the emergency they

shall reach the assembly point without delaying further to ensure their safety and security.


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The assembly point should be clearly marked with directional display board along the route. Route should be well lighted with florescent marking.

During an emergency, pre-designated persons would take charge of this point and take the roll call of the people reporting. Provisions should be made for assembly points, communication and headcount facilities at assembly points, and personnel to control the movement of assembled employees. S.No. Name of

Plant/Unit/Area/Building Location of AssemblyPoint

Area Coordinator

1 Site office Near Entry Gate Security

2 Training Center In front of training center Security

vi. Declaration of on-site and off–site emergencies

1) An emergency starts as a small incident which may become a major incident with passage of time. At the initial stages, the emergency organization chart shall be put into action. If the incident goes beyond control the on-site emergency plan will be actuated by the chief incident controller at the appropriate stage as considered necessary.

2) During idle shift or holidays, the security personnel will combat the incident as per the ONSITE EMERGENCY PLAN (OEP) organization chart and at the same time inform various emergency controllers for guidance and control the situation.

3) When emergency becomes catastrophic and evacuation beyond the plant premises is considered necessary by the chief incident controller, the situation will be handed over to district authority for implementing the off-site emergency plan.

4) The management of emergency henceforth has to be controlled by the district crisis management group under the supervision of the District Collector/DDMA.

In addition to preparation of on-site emergency plan, furnishing relevant information to the district authorities for the preparation of off-site emergency plan is a statutory responsibility of the occupier of every industry handling hazardous substance.

vii. Medical Facilities

a. Details of Medical Facilities Inside the Plant

Ziraand Talwandi Bhai is a major location, which has Hospitals. The range of medical facilities available in the city is very wide and all major hospitals have


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specialized treatment units for a wide variety of ailments and medical conditions. It has therefore not been required by any organization to build up its strong in-house facilities. b. First Aid Boxes A first aid centre with adequate facilities shall be provided. It shall be maintained round the clock. Four first aid boxes have been provided at various work stations to take care of first aid in case of any injury.

c. Medical Facilities Available Outside the Plant

List of the Medical Facilities Available outside the plant is:

d. Emergency Transport Facility

Sr No Name of agency Location Number & Type Contact no. Service Type

1 Osahan Hospital Zira 02 Ambulances 9815160152 Paid 2 Own Factory

Premises 03 Passanger Cars

Emergency Control Centre

e. Lists of Antidotes and Emergency Medicines

The following medicines are available in the First Aid Boxes: Burnol Dispirin Sterile Gauze Surgical Dressing Gauze Dressing

Sr No Name of The Hospitals Location Distance From Site

Telephone Numbers

1 Osahan Hospital Ferozepur Road Zira

8 KM 9815160152

2 Civil Hospital Zira 8 KM 3 Dr. V P Chawala Hospital Talwandi Bhai 8 KM 94171-22186 4 Civil Hospital Talwandi Bhai 8 KM 9780096696


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Potassium Permanganate Iodine Tincture Cotton Scissors Savlon In addition, Snake antivenom is also available in the plant.

viii. Evacuation

1) Planning and training on evacuation techniques are important in preventing injuries. Evacuation of local communities or people near the site may be prudent depending on the situation and down-wind dispersion information etc. Although this action will normally be initiated and handled by district authorities, the affected installation shall help to implement such evacuation.

2) This evacuation plan shall also consider: a. basis for recommending on-site or off-site actions b. authorize person for area or site evacuation c. mode of communication d. training in locating exits from buildings, areas and the site e. location of escape equipment f. provisions for flashlights or other supplemental lighting g. which areas can function as safe area h. moving crosswind from gas or fume releases, etc. i. provision of food and drinking water at assembly point and transfer point.

3) If evacuation takes place after initial head counts are reported, means for

recounting may be necessary. Where it is safe to do so, areas being evacuated should be thoroughly searched to ensure everyone has departed safely. Portable mobile vehicle for announcement should be available in the emergency.

ix. Information to Public

The safety measures to be taken in the event of an emergency shall be made known to the general public who are likely to be affected. For the purpose, use of Dos' and Don‟ts' shall be prepared and furnished to the Crisis

Management Group. Display boards carrying do‟s and don‟ts should be located


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outside the gate as well as in the neighboring colonies and other habitat areas in the immediate vicinity.

x. Reporting of the Incident

All incidents covered under Level-I should be maintained by the entity for inspection whenever called for inspection and Level-II and Level-III shall be reported to the Board in the format specified and placed in Annexures including near miss incident. The above report should be submitted within 48 hours after occurrence of the incidents or any other reason triggering major incident. Investigation report of all major incidents shall be submitted to the Board. An incident shall be treated as Major if any of the following occurs; a) fire for more than 15 minutes b) explosion / blowout c) fatal incident. d) loss above Rs. 10.0 Lac e) cumulative man hours lost more than 500 hrs. f) plant shutdown / outage due to the incident g) Level-III incident

xi. Action after reporting of incident by the entity

After reporting of the incidents to Board, Nodal officer of the Board (head of Technical Standards the specifications and safety group) shall have responsibility of informing all the Members of the Board and shall coordinate with appropriate level in National Disaster Management Authority (NDMA) till normalization of the situation.

xii. Termination of emergency

Termination activities should concentrate on giving accurate information to people who need it most especially employees, neighborhood, District Authorities engaged in offsite emergencies, and should begin as soon as the emergency phase of the operation is completed. The termination of emergency shall be declared through siren as per the Siren Code defined by industry in case of Level- I and II. For Level-III termination of emergency shall be declared by District Authority through appropriate mode of information transfer so as to reach each and every one.


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xiii. Emergency Recovery Procedures

After the emergency, the following activities need to be carried out in detail. a) information to statutory authorities. b) incident investigation. c) damage assessment. d) salvage of products, de-contamination, clean-up and restoration. e) a detailed report shall be prepared based on the entire experience of the incident,

including restorations, limitations and lessons learnt. f) ambient air monitoring at the site as well as 5 km radius of the installation by State

Pollution Control Board to determine the contamination level affecting health.

xiv. Integration of the ONSITE EMERGENCY PLAN (OEP) with the NATIONAL DISASTER MANAGEMENT PLAN (NDMP)

a. NATIONAL DISASTER MANAGEMENT PLAN (NDMP)

On 23 December 2005, the Government of India took a definite step towards NDMP by enacting the NDMP ACT, 2005. The NDMP Act, 2005 is a Paradigm Shift from a response and relief-centric approach to a proactive and comprehensive mindset towards NDMP covering all aspects from prevention, mitigation, preparedness to rehabilitation, reconstruction and recovery. Similar to National Authority at the Centre, the State Government is to establish a State Disaster Management Authority for the State. The State Authority is to be headed by the Chief Minister of the State as the Chairperson. Every State Government, in turn, is to establish a District Disaster Management Authority for every district in the State with the District Collector as the Chairperson. The Central Government is empowered to take further measures as it deems fit for the purpose of disaster management like deployment of naval, military and air forces, other armed forces of the Union or any other civilian personnel as may be required for the purposes of this NDMPAct. Government of India is empowered to establish institutions for research, training, and developmental programs in the field of disaster management as per this Act. The national vision is to build a safer and disaster resilient India by developing a holistic, proactive, multi-disaster and technology driven strategy for NDMP. This will be achieved through a culture of prevention, mitigation and preparedness to reduce the impact of disasters on people. The entire process will centre stage the


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community and will be provided momentum and sustenance through the collective efforts of all government agencies supported by Non-Governmental Organizations (NGOs). National Disaster Management Structure showing the interactive linkage among various agencies for synergized management of disaster is given below;

Note: Since PNGRB has been constituted by PNGRB Act, 2006, it should be identified under Ministries / Departments of Govt. of India.

Abbreviations for NDMA:


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NDMA : National Disaster Management Authority NEC : National Executive Committee DM : Disaster Management NCC : National Cadet Corps NCDM : National Committee on Disaster Management NDMRCs : National Disaster Mitigation Resource Centres NDRF : National Disaster Response Force NSS :National Service Scheme NYK :Nehru Yuva Kendra NGOs : Non-Governmental Organizations SDMA :State Disaster Management Authority SEC :State Executive Committee DDMA :District Disaster Management Authority

b. Integration of ONSITE EMERGENCY PLAN (OEP) with NDMP

This ONSITE EMERGENCY PLAN (OEP) document has been developed taking into account all possible inputs on the subjects from various stake holders. Efforts have also been made to synergize this with the document on National Disaster Management Guide (Chemical Disasters) Industrial brought out by National Disaster Management Authority.

xv. Security Threat Plan

1) With increase in terrorist activities towards the end of 20th century and installations having, significant role in national economy, sabotage and bomb threats to such installation should also be considered in the disaster management plan. Such as high level of alertness measures, strengthening security measures by security gadgets mechanical and electronic security gadgets. In any of such situation, city police/ administration should be informed immediately and their help should be sought.

xvi. Off-Site Emergency Plan

The Off-site Emergency Plan, which is the responsibility of the District Emergency authority, deals with measures to prevent and control emergencies affecting the public and the environment. This plan considers the possible effects of incidents from any industry on the neighboring population and the remedial measures. In this context, Malbros will furnish to the District Emergency Authority the following technical inputs to enable it to prepare the contingency plan accordingly:


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Inventory of hazardous chemicals MSDS of such chemicals Types of emergencies Nature, extent and likely effects of such incidents Risk and Environmental Impact Assessment The District Emergency Authority, based on severity of any emergency in product

distribution network will declare off-site emergency

a. Educational Programs

The plant management shall periodically undertake a comprehensive awareness program for dealers, tank truck crew and contractors. The educational material shall be prepared in local, Hindi and English language. Local audio visual media available should be used for such educational programs. Need based participation of the local district authority, regional transport office, local fire service department and local police shall be considered.

b. Investigation of Asset/Equipment Failure

Besides reporting and recording of all instances of asset related failures, damage to the environment and third party property shall also be recorded. Failure investigating team shall comprise of personnel trained in failure investigations. The data from all failure occurrences should be analyzed for trends so that proper initiatives including training could be taken to minimize failures.

c. Prevention of Accidental Ignition

Site Specific Risk Assessment should be carried out before commencing any repair activities. The outcome of such risk assessment should be documented and considered while preparing safety plan for the repair work. No hot work should be undertaken without proper work permit issued by authorized personnel. Specific consideration shall be given during simultaneous operations by different contractors with likely overlap of their operations.

d. Responsibilities of Malbros in Off-Site Emergency Plan

Malbros shall identify and evaluate incident scenarios that would create hazardous conditions in the area adjacent to the product distribution network and routes of tank trucks and dealers location for public distribution .The extension of critical on-site major incidents like major fire or explosion to an off-site location crossing the perimeter of Malbros should be informed immediately to the local governmental agencies to take charge of the situation


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Malbros shall extend a specialist advice and other emergency equipment‟s/

facilities to assist local authorities in mitigating major incidents like fire, explosion, spill, major road accidents, natural calamities etc.

Malbros shall establish a channel of communication with the local authorities for emergency communication

Thus, all the possible external coordination / liaison with a view to mitigate and minimize the incident impact / consequence outside plant boundary shall be done within the shortest possible time.

xvii. Plan Updation

It is necessary that the Emergency Plan is reviewed and updated upon the following situations:

Lapses / problems identified during emergency exercises and real incidents. During any major changes/modifications in operating facilities or emergency

equipment‟s Accident/incident investigation process(reported internally as well as from

external occurrence) and the recommendations therefrom Changes in the organization structure / communication facilities, rescue and

support means and their identities Health /safety audits reports At least once in two years at the minimum

xviii. Glossary

DMP Disaster Management Plan NH No hazard from the event

OEP Onsite Emergency Plan NR Impact criteria level Not Reached

HAZCHEM Hazardous Chemical IRPA Individual Risk per Annum

CFO Chief Fire Officer UVCE Unconfined Vapour Cloud Explosion

HSE Health Safety Environment MSDS Material Safety Data Sheet

TT Tank Truck QRA Quantitative Risk Assessment


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15. HAZARD IDENTIFICATION, HAZARD ANALYSIS AND RISK ASSESSMENT

Sr. No. Check-point 1 Which of the following procedures or techniques for hazard identification has

been used in the IRD/ installation : 1) HAZOP/HAZAN 2) Incident Consequences and Analysis 3) Event Tree Analysis 4) Fault Tree Analysis 5) Failure Modes, Effects and Criticality Analysis 6) Risk Assessment 7) What if, analysis 8) Other accredited practice

Hazard Identification : 2 Is the installation covered under the definition of “Major Incident Hazard

Installation” as per the Manufacture Storage and Import of Hazardous

Chemicals Rules 1989 (Amended 1994 and 2004. If yes, please specify the site notification and safety reports

3 If yes, whether major Incident hazards identified and steps taken for their prevention

4 Whether design deficiencies, failures or errors which can contribute to hazards and cause abnormalities leading to an Incident are identified

5 What are the measures undertaken to counter above deficiencies or, errors 6 Consequences of a major Incident on the workers, people in the

neighborhood and the environment are considered 7 Steps envisaged for mitigation of the consequences of such incident 8 Does the installation produce / handle / use / import / store any hazardous

chemicals as defined under MSIHC Rules 1989 (Amended 1994 and 2004) 9 If yes, whether a list of these chemicals, preferably in alphabetical order with

their maximum licensed storage quantities is displayed 10 Are material safety data sheets (MSDS) of these chemicals are prepared /

obtained in the prescribed format as per MSIHC Rules and State Factory Rules

11 Whether a system for disseminating information about these MSDS to concerned workers are existing

12 Are there a system of labeling of containers / storage tanks for the chemicals / hazardous substances


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13 Whether estimation of maximum possible quantity of each hazardous substance are considered including any vehicle (TT/TW) on site or within 500 mtrs of the site.

14 Whether location, configuration and condition under which the hazardous substances are stored and handled are clearly declared

Vulnerability Analysis : 15 Whether zones of influence or vulnerable zones are estimated by considering

the maximum single storage of hazardous substance and maximum loss scenario

16 Whether effects of influence on the vulnerable zones are made after considering the population, facilities and environment encompassed inside that zone

Risk Analysis : 17 Whether a relative measure of the probability and consequences of various

possible hazardous events including worst case scenario are taken into account 18 Whether risks are calculated by multiplying the probability of occurrence of

each event by the consequences of that event and then summing up the results. 19 Whether all types of events possible in petroleum installations are considered

including i) storage tanks on fire, ii) pool fire [burning pool of liquid fuel], iii) Flange joint leakage in pipelines, iv) Fire in TT or TW gantry, and v) rupture of hoses.

Risk Reduction Measures : 20 Whether measures for reduction of identified high risks are included by

reducing the consequences through hazard mitigation measures 21 Whether steps have been considered to reduce risks to the exposed population

by increasing safe distances by acquiring property around the facility, if possible

HAZOP Study 22 Whether the above method is applied if the location handles more than

specified storage and / or critical operations 23 Whether the study systematically identifies all possible deviations from

normal operations 24 Whether risk levels are established for each deviation after considering the

probability and consequences of each such events 25 Whether potential means for detection of such events and preventive measures

are recommended by the study


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16. INCIDENT PREVENTION MEASURES

Sr. No. Check-point 1 Whether Safety, Health and Environment Policy of the location is displayed

2 Whether the Safety Policy is documented and duly approved by the top management

3 Whether the Safety Policy is well structured to cover all elements of Safety, Health and Environment protection

4 Whether the layout is convenient from operation and safety aspects and meets minimum distance norms

5 Whether a duly constituted Safety Committee is functioning in the location with representation from workmen/staff

8 Whether all unsafe developments and likely risks are deliberated in the meetings and appropriate steps are recommended for eliminating such risks

9 Whether compliance status of recommendations of earlier Safety Committee meetings are discussed before taking up new issues.

10 Whether performance and shortcomings observed during recent mock disaster drills form part of the discussions in safety committee meetings

11 Is the safety committee minutes are recorded and signed by all the attending members

13 Whether periodical safety audits and inspections by internal and external audit teams are conducted in defined intervals

14 Whether a system of regular monitoring of such audit compliances by controlling offices / HO are in place

15 What is the composition of external audit teams to ensure impartiality of audit findings

16 Whether Work Permit System have been implemented

17 Whether work permits are issued for hot work, cold work, electrical work and vessel entry jobs

18 Whether the location-in-charge or his authorized nominee remain the issuer for all hot work and vessel entry permits for enhanced safety and control.

19 Whether work permits are duly closed at completion of the stipulated jobs, duly certified by the supervising officer

20 Whether heat detectors in tank sprinkler systems, high level alarms of tank farm management system are provided and checked for regular functioning

21 Whether in-built safety interlocks provided in the design are adequately specified and checked for regular functioning


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17. POST EMERGENCY - RECOVERY MEASURES Sr.No. Check-point Salvage of product 1 Check that spilled / accumulated product contents are transferred to the OWS or

collected in drums. 2 Check whether the quality and quantity estimation of the product extracted from

OWS has been done for further disposal in line with standing QC guidelines by either transferring to service tanks or to nearest refinery for blending / reprocessing or not.

3 Check that correct stock accounting of spilled product as loss has been completed in accounting system.

4 Check that affected area has been completely cleaned and dried after evacuation of spilled product.

5 Declare that affected area after salvage operations is fully clean and safe for movement of the working personnel.

6 Check that all drains are not having any residual oil/product and are thoroughly cleaned and dried.

7 Check that all control valves on product lines and OWS lines outside dyke area and drains are completely closed after removal of the spilled product.

8 Check that interlocking system of tanks / gantry has been re-activated for normal operations.

9 Check whether the soil testing of the affected area, if required, has been done to assess the soil contamination level to meet the Environmental – SPCB norms / requirements.

Taking care of affected manpower 10 Whether physical accounting of all personnel on duty during and after the incident are

ascertained by the Site Incident Controller and reconciled immediately 11 Whether the first-aid treatment and post-incident health check of the affected

personnel has been undertaken in time 12 Whether these personnel are declared fully physically fit before allowing them to

resume their normal duties 13 Whether the records for such first aid and treatment of the affected personnel are

maintained in a well-defined format Addressing media and outside bodies 17 Whether the incident was appropriately informed to the local media in line with the

respective company‟s Press and Media Policy 18 Whether the role of neighboring population during the drill / disaster is suitably

informed to the population during subsequent meetings with local administration / panchayat etc. for necessary improvements

19 Whether the awareness and preparedness on disaster is regularly assimilated / shared with nearby public / societies and stake holders.

Reporting


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20 Check whether that disaster incident report was communicated to respective controlling office / HQ promptly in a standard format.

21 Whether the incident reports are also sent to concerned State Level Industry Coordinator on time.

22 Check that detailed report on disaster in proper format was communicated to Factory inspector / Labour inspector / SPCB / District Magistrate.

Investigation 23 Whether investigation teams are constituted as per respective company policies 24 Whether RCA (Root Cause Analysis) of the disaster is conducted by the investigating

team 25 Whether detailed investigation into effective functioning of interlocks, detection

devices, automation controls and applicable norms are carried out to find out possible improvements in design / construction / operations / maintenance and training aspects etc.

26 Whether a system of initiating appropriate corrective measures including suitable revisions to the Disaster Management Plan are adopted based on findings of the investigation

Damage Assessment – Monetary and Physical 27 Check the valuation / cost of product loss / down gradation on account of

contamination, if any / Property / Structures / damaged assets – equipments. 28 Whether repairs and maintenance cost of property, assets and equipment are assessed. 29 Whether any penalty by statutory authorities like SPCB / Factory Inspector and

Labour Commissioner are assessed. 30 Whether possible impact on environment are also assessed and appropriate measures

are taken 31 Whether damage assessment also include potential erosion of reputation – from

company, industry and national perspectives Clean up and Restoration 32 Whether the affected area has been fully cleaned and cleared after due clearance from

investigation team 33 Check whether heat detectors, high level alarms, in built safety systems (NRV, TSV

etc.) are fully functional after the disaster incident. 34 Check whether all firefighting equipment like – hoses / nozzles / Fire Extinguishers

etc. have been put back at designated places and are fully ready for reuse 35 Whether clear procedures are in place to allow resumption of normal operations


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18. IMPORTANT TELEPHONE NUMBERS

LOCAL ADMINISTRATION Fire Brigade Contact No. Control Room 101 Central fire station Zira 01682-2749619 Fire Station Ferozepur 01632-101,9463109501

Fire Station Moga 01636-220123,101

Ambulance Osahan Hospital Zira (02 Nos.) 9815160152

District Authorities Contact No. Deputy Commissioner, Ferozpur 01632-244006,008

Sr. Superintendent of Police, Ferozpur 01632-246697,244049

SDM Zira 01682-250117

DSP Zira 01682-250150,9646292176

Police Station Zira 01682-250185,183

SHO Zira 01682-250185,183

CMO/ SMO 01632-245173,242964 Sarpanch Mansoorwal

Sarpanch Ratoul 9814135579

Sarpanch Sanehar 9814555622

Deputy Directors of Factories 9463871982

Assistant labor Commissioner 01632-245317 Punjab Pollution Control Board ASR 9878950554 KEY PERSONAL OF M/s MALBROS INTERNATIONAL PVT. LTD. Name Designation Contact No. Mr. Pawan Bansal CAO 9914800006 Mr. Munish Tyagi AVP(Tech) 9781219007 Mr. Brijesh Srivastava Head -Operations, 9914919007 Mr. Y.S. Parihar Head Bottling Operation 9914932653 Mr. Rajinder Singh Head Purchase 9914932868 Mr. Dalbir Singh Head – Maintenance, 9914932277 Mr. S.K. Srivastava Head -Electricals, 9914932867 Mr. Vikram Singh Bedi Head –Mechanical 9914932866 Mr. Vinod Kumar Head – Civil, 9914948822 Mr. Satinder Singh In charge - Fire & Safety 9914932837 Mr. Lakhwinder Singh Head - Security 9914932839 Dr. Jaswant Singh Medical Officer 9815160152


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19. FIRE FIGHTING EQUIPMENT & PERSONAL PROTECTIVE EQUIPMENT

Sr. No. Type of Equipment Capacity UOM Quantity 1 Fire Water Tank 200 KL 1 2 Fire Water Tank 200 KL 1 3 Bore Well 50 KL/Hr. 2

4 Fire Water Pump(Diesel Engine Driven)

171 KL/Hr. 2

5 Jockey Pump(Electric Motor Driven)

10.8 KL/Hr. 2

6 Mobile Foam Trolley 50 Ltr. 9 7 Mobile Foam (A+B) 9 Ltr. 14 8 Dcp Fire Extinguisher 10 Kg 3 9 Dcp Fire Extinguisher 5 Kg 4 10 Dcp Fire Extinguisher 6 Kg 10 11 Co2 Fire Extinguisher 4.5 Kg 15

12 Safety Helmet One per person

-- 25

13 Safety Shoes -- Pair 10 14 First Aid Box -- Kit 5 15 Rubber Hand Gloves (Nitrile) -- Pair 2 16 Electrical Hand Gloves 33 KV 2 17 Safety Goggle -- -- 24 18 Ear Muff -- -- 4 19 Ear Plug -- -- 12 20 Nose Mask -- -- 10 21 Electrical Siren 3 Km 0 22 Hand Operated Siren 1 Km 0 23 Red & Green Flag For Fire Drill -- -- 01 in each col 24 Hose Box -- -- 10 25 Fire Hose -- -- 20 26 Sand Drum With Scoop -- -- 1 27 Sand Buckets -- -- 12 28 Jet Nozzle -- -- 12 29 Universal Nozzle -- -- 4 30 Water curtain nozzle -- -- 2 31 Non-sparking Tools -- Kit 2 32 Oil Absorbent Kit -- Kit 1


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20. PRODUCT STORAGE CAPACITY AND CHEMICAL DATA

EXTRA NEUTRAL ALCOHOL / RECTIFIED SPIRIT/ IMPURE SPIRIT RECEIVER SAND STORAGES Sr.No. Tank Name Unit Capacity 1 Receiver No-1 KL 60 2 Receiver No-2 KL 60 3 Receiver No-3 KL 60 4 Receiver No-4 KL 15 5 Receiver No-5 KL 45 6 Receiver No-6 KL 100 7 Spirit Storage No-1 KL 750 8 Spirit Storage No-2 KL 750 9 Spirit Storage No-3 KL 105 10 Spirit Storage No-4 KL 200 11 Spirit Storage No-5 KL 165 12 Spirit Storage No-6 KL 165

CHEMICAL DATA

SL NO

NAME OF THE CHEMICAL

COMMERCIAL TECHANICAL NAME

STORAGE QUANTITY

METHOD OF STORAGE

BELOW/ ABOVE THE GROUND

1

Ethanol (96% conc.)

Extra Neutral Alcohol

2500 KL

Tanks

Above the ground & Separate Room

2 Liquor ammonia Liquor ammonia 1000 Liters Liters

Above the ground & Separate Room

3

Lubricant Oil

Lubricant Oil

10 Barrels

Barrels

Above the ground

4

Hydrochloric acid

Hydrochloric acid 10 Cans Cans Above the ground

5 Sulphuric acid Sulphuric acid 01 Cans Cans Above the ground

6

Servo Lubricant Oil

Servo Lubricant Oil 02 Barrels Barrels Above the ground & Separate Room

7 Alum Alum 20 Solid Lump

Above the ground


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