ICE MAKE REFRIGERATION PVT. LTD
SURVEY # 226 / 227, DANTALI INDUSTRIAL ESTATE, GOTA – VADSAR ROAD, VIA AHMEDABAD, AT.: DANTALI,
TA. KALOL, DIST.: GANDHINAGAR – 382721 PH. NO. : 098791 07881 / 784
Website: www.icemakeindia.com Email: [email protected]
On-Site Emergency Plan
(December - 2015)
Prepared By
Shriji EHS Management Services
Ahmedabad
Preface
The management of ICE Make Refrigerations Pvt. Ltd. Survey no. 226 ,227, Dantali Industrial Estate , Gota-vadsar Road, At.: Dantali, Ta,:Kalol , Dist.: Gandhinagar has entrusted us for the task of preparing on-site emergency plan for their expansion work. Accordingly, We have prepared on-site emergency plan for any emerging out of storage, use, handling and transport of hazardous chemicals to be used in the plant area.
The factory is proposed to store hazardous chemicals and hence it falls under category ‘Hazardous Process’ i-e section (2cb) of factories Act. Hence management has decided to prepare On Site emergency Plan. And once plan is prepared, it is decided to conduct mock drill. This is the management’s pursuance regarding hazards and measures to be taken in case of any emergency while operating the plant.
We have tried fully to prepare the plan as per the data provided by the management. Mr.Rajendrabhai Patel - Director and Mr. Hirenbhai Limbachia – HR
& Safety Dept. , have extensively participated in preparing the plan.
The plan will be useful to the management in combating emergency.
Place : Ahmedabad Date : 28/12/2015
Shriji EHS Management Services
INDEX
Sr.NO. Content Page
Part – I (Guidelines)
1 Preface 2
2. Chapter-I Preliminary 5
3. Chapter-II Risk and Environmental Impact Assessment 12
4. Chapter-III Emergency Organization 22
5. Chapter-I V Communication System 29
6. Chapter-V Action on site 33
7. Chapter-VI Off-site Emergency Plan 40
8. Chapter-VII Training, Rehearsal and Records 43
9 Chapter-VIII First Aid 45
Annex No. Part – II (Annexure Section)
1. Identification of the factory 48
2. Map of the Area 49
3. Factory Layout 50
4. Storage Hazards and Controls 51
5. Material Safety Data sheets 52
6. Process and Vessel Hazardous and Controls 64
7. Other Hazards and Controls 65
8. Trade Waste Disposal 66
9. Records of Past Incidents 67
10. Gas Dispersion Concentrations 68
11. Evacuation Table 69
12. Environmental Impact Assessment 70
13. Weather Conditions 71
14. Incident Controllers 72
15. Deputy Incident Controllers 73
16. Site Main Controller 74
17. Key Personnel 75
18. Essential Workers 77
19. Assembly Points 78
20. Emergency Control Center 79
21. Fire & Toxicity Control Arrangements 80
22. Medical Arrangements 83
23. Transport and Evacuation Arrangements 84
24. Pollution Control Arrangements 87
25. Other Arrangements 88
26. Alarms and Sirens 89
27. Internal Phones 90
28. External Phones 91
29. Nominated Persons to declare Major Emergency 92
30. Form to record Emergency Telephone Calls 93
31. Statutory Communication 94
32. Separation Distances 95
33. Emergency Instruction Booklet 96
A List of Fire Extinguishers 100
B List of First-Aid Boxes 101
C List of Personal Protective Equipments (PPES) 102
D Health Check –up Records 103
E List of Sand Buckets 105
F List of Safety Guards 106
Emergency procedure – local language 107
PART – I CHAPTER – 1 PRELIMINARY 1.0 INTRODUCTION OF EMERGENCY PLAN
Today’s world produces many kind of chemicals in enormous quantities, probably beyond safe manageable levels, and that too in many cases with record speed.
People working in chemical factories, transporting the chemicals and using chemicals are constantly exposed to chemical hazards like explosion, fire, gas leakage, spillage of chemicals etc.
Disaster means accident causing catastrophic situation in which the day to day patterns of life are in many instances, suddenly disrupted and people are plunged in to helpless ness and suffering and as a result need protection, clothing, shelter, medical and social care and other necessities of life.
Disaster may occur by natural phenomenon or by men or by men’s impact upon the environment. This plan has been prepared in view of the potential hazards prevailing in our factory and in the surrounding area.
A sincere effort is made to give action plan for all other not only ourselves but for concerned agencies such as workers, office staff, general public, surrounding people, fire brigade, transporters, Government Authorities etc
This plan is in two parts. The first part explains basic requirements, definitions, objectives, hazard identification, risk analysis and environmental impact assessment, organizational set up, communication system, actions on site, link with off-site emergency plan and the aspect of training, rehearsal and records
.
The second part is given as ‘Annexure Section’ containing 33 useful annexure. The information in annexure will also be useful to our unit as well as to the surrounding units as a ‘mutual aid’ and to the Government in preparing Off-site Emergency Plan under Chemical Accidents (Emergency Planning, Preparedness and Response) Rules 1996. It reveals strengths and weaknesses in the plan and suggests residual preparedness if any.
1.1 ABOUT ORGANISATION
M/s. ICE MAKE Refrigerations Pvt. Ltd. proposes for the expansion of the existing manufacturing capacity of refrigeration units, with manufacturing of PUF at site. The existing unit is located at Survey no. 226 ,227, Dantali Industrial Estate , Gota-vadsar Road, At.:
Dantali, Ta:, Kalol , Dist.: Gandhinagar , company is proposing the expansion of existing unit within this premises .
There will be no requirement of new construction , as having existing setup for infrastructure as well as of existing manufacturing set up. The unit will employ @ 180 no. of direct labours, staff and contractor’s labours and indirect employment after the expansion.
The Product name and capacities are shown here in table 1.
Table -1 - LIST OF PRODUCTS AND RAW MATERIALS WITH THEIR QUANTITIES
A. The Product details with capacities (existing and proposed) Product name
Existing capacity, Unit/month
Proposed expansion in Unit/month
Total capacity in Unit/month All type of Commercial &
Industrial Refrigeration Equipment using PUF
200 nos. 1000 nos. 1200 nos.
B. The Raw Materials Consumption details (existing and proposed) Raw material Existing
(kg/Month)
Expansion (kg/Month)
Total (kg/Month) Polyol
(1,1-dichloro-1-
fluoroethane (HCFC – 141b)
Tris (2-chloro-1- methylethyl) phosphate)
- 26,400 26,400
Diphenyl Methane
Di-isocyanate (MDI) - 34,200 34,200
C. Fuel Consumption
Fuel name Consumption
Existing Expansion Total
HSD 10 lph - 10 lph
(Reusing) Wood Frames (waste
materials) received in Packing materials of Raw Materials
- 20 kg/day 20 kg/day
D. The Raw Materials Fitting Assembly details (existing and proposed) No. Raw material Existing
(Unit/Month)
Expansion (Unit/Month)
Total
(Unit/Month)
1 Compressor 192 nos 950 nos 1,142 nos
2 Condenser 190 nos 950 nos 1,140 nos
3 Aluminum checker plates
360 nos 1,800 nos 2,160 nos
4 Condenser unit 10 nos 50 nos 60 nos
5 Copper tubes 3,000 kgs 15,000 kgs 18,000 kgs
6 Door closer 180 nos 900 nos 1,080 nos
7 Fan motors 380 nos 1,900 nos 2,280 nos
8 Refrigerant
A 404 CFC free 135 kgs 675 kgs 810 kgs
B R – 22 - 150 kgs 150 kgs
C R - 134 - 300 kgs 300 kgs
9 Gasket (door) 850 MTR 4,250 MTR 5,100 MTR
10 G. P. Sheet 23,500 kgs 1,17,500 kgs 1,41,000 kgs
11 Handel 170 nos 850 nos 1,020 kgs
12 Heater 22 nos 110 nos 132 nos
13 Hingis 320 nos 1,600 nos 1,920 nos
14 M. S. Angel 3700 kg 18,500 kgs 22,200 kgs
15 PVC Door Profile 490 MTR 2,450 MTR 2,940 MTR
16 S. S. Angel & Sheet 5,000 kg 25,000 kgs 30,000 kgs
17 Heat Exchanger - 11 nos 11 nos
18 Evaporator - 60 nos 60 nos
1.2 IDENTIFICATION OF THE FACTORY :
Annexure-1 gives basic information about the factory.
1.3 FACTORY LAYOUT PLAN
Factory layout plan showing the various details required for emergency preparedness such as entry and exit gates, plant, storage area, emergency control center, assembly
point, location of process and non chemical vessels, etc. shown in the enclosed Annexure – 3.
Area of the factory is sufficient for safe working and factory compound and building are well maintained. Ways and passages are free from obstruction.
1.4 VARIOUS USEFUL DEFINITIONS
Some definitions relevant to emergency planning are given below 1.4.1 ACCIDENT
An accident is an unplanned event, which has a probability of causing personal injury or property damage or both. It may result in physical harm in the shape of injury or decease to people, damage to property, loss to the company, a near miss or any combination of these effects.
1.4.2 MAJOR ACCIDENT
A major accident is a sudden, unexpected, unplanned event, resulting from uncontrolled developments during an industrial activity, which causes, or has the potential to cause – (a) Serious adverse effects immediate or delayed resulting to death, injuries,
poisoning or hospitalization to a number of people inside the installation and / or to persons outside the establishment.
(b) Significant damage to crops, plants or animals, significant contamination of land, water or air.
(c) An emergency intervention outside the establishment e.g. evacuation of local population, stopping or local traffic.
(d) Significant changes in the process operating conditions such as stoppage or suspension of normal work in the concerned plant for a significant period of time.
(e) Any combination of above effects.
1.4.3 EMERGENCY
An emergency could be defined as any situation, which presents a threat to safety of person and/or property. It may require out side help also.
1.4.4. MAJOR EMERGENCY
A major emergency occurring at a work is one that may affect several departments within
disruption outside the works. It will require the use of outside resources to handle it effectively.
Usually the result of a malfunction of normal operating procedures, it may also be precipitated by the intervention of an outside agency, such as a sever electrical storm, flooding, crashed aircraft or deliberate acts or arson or sabotage
Emergency due to operating conditions such as uncontrolled reactions, small fire, small gas leak, spill, failure or power, water, air, steam, cooling media, scrubbing media etc.
and which can be locally handled by plant personnel without outside help is not considered as major emergency. Operating instructions in the safety manual shall cover this area, though the on-site emergency plan will also be useful.
1.4.5 DISASTER
Disaster is a catastrophic situation in which the day – to – day patterns of life are in many instances, suddenly disrupted and people are plunged in to helplessness and suffering, and as a result need protection, clothing, shelter medical and social care other
necessities of life, such as:
a) Disasters resulting from natural phenomena like earthquakes, volcanic eruptions, storm, surges, cyclones, tropical storms, flood, land slides, fierce fires and massive insect infestation. Also in this group, violent draught which will cause a creeping disaster leading to famine, disease and death must be included.
b) Second group includes disastrous events occasioned by man, or man’s impact up on the environment, such as armed conflict, industrial accidents, factory fires, explosions and escape of toxic gases or chemical substances, river pollution, mining or other structural collapses, air, sea, rail and road transport accidents, aircraft crashes, collisions of vehicles carrying inflammable liquids, oil spills at sea and dam failures.
1.4.6 HAZARDS
Hazard is a physical situation, which may cause human injury, damage to property or the environment or some combination of these criteria.
1.4.7 RISK
Risk is the likely hood of an undesired event (i.e. accident, injury or death) occurring with a specified period or under specified circumstances. It may be either a frequency or a probability depending on the circumstances.
1.4.8 THE ON-SITE EMERGENCY PLAN
The on-site emergency plan deals with measures to prevent and control emergencies within the factory and not affecting outside public or environment.
1.4.9 THE OFF-SITE EMERGENCY PLAN
The off-site emergency plan deals with measures to prevent and control emergencies affecting public and the environment outside the premises. The manufacturer should provide the necessary information on the nature, extent and likely effects of such incidents.
1.5 OBJECTIVES OF THE EMERGENCY PLAN
An emergency can not be always prevented, but it can be controlled within limits and its effects can be minimized by using the best resources available at the time.
Emergency planning is a management’s function and it should not be considered in isolated. Management should evaluate the activities, operations and processes carried out within the works before starting to plan an emergency operation.
A check must be made to ensure that all required steps have already been taken which are included in emergency planning.
Considering our number of employees, materials and processes, availability of resources, location of site, size and complexity of the works, we have prepared this emergency plan.
In our plan, we have shown the clear instructions without overlap or confusion for all concerned staff members. The same details are prepared as per Annexure No. 33
1.5.1 THE OBJECTIVE OF THE EMERGENCY PLANNING ARE AS UNDER
(a) To define and to assess emergencies, including risk and environmental impact assessment.
(b) To prevent the emergency turning into a disaster.
(c) To safeguard employees and people in vicinity.
(d) To minimize damage to property or / and the environment
(e) To inform employees, the general public and the authority about the hazards / risks assessed, safeguards provided, residual risk if any and the role to be played by them in the event of emergency.
(f) To be ready for “Mutual Aid” if need is raised to help neighboring unit. Normal jurisdiction of an OEP is the own premises only, but looking to the time factor in arriving the external help or off-site plan agency; the jurisdiction must be extended outside to the extent possible in case of emergency occurring outside.
(g) To inform authorities and mutual-aid centers to come for help.
(h) To effect rescue and treatment of casualties.
(i) To identify and list any dead.
(j) To inform and help relatives.
(k) To secure the safe rehabilitation of affected areas and to restore normalcy.
(l) To provide authoritative information to the new media.
(m) To preserve records, equipments etc. and to organize investigation into the cause of the emergency and preventive measures to stop its reoccurrence.
(n) To ensure safely of the works before personnel re-enter and resume work.
(o) To work out a plan with all provisions to handle emergencies and to provide for emergency preparedness and periodical rehearsal of the plan.
CHAPTER – 2
RISK AND ENVIRONMENTAL IMPACT ASSESSMENT
2.0 INTRODUCTION
Identification, analysis and assessment of hazards and risk provide vital information to Risk Management.
Due to non-availability of failure rate data, reliability rate, gas dispersion rate, suitability of Industry for Indian environment, acceptable criteria for risk to public and environment etc. the complete Risk Assessment is not possible.
Based on available data, we have made the hazard identification for our factory. While doing so, best available technology is used in design, installation, operation and maintenance of different processes, plants, equipments and machineries.
There are mainly three hazards in our factory:
(a) Fire hazards
(b) Spillage of chemicals.
(c) Toxic release
2.1 AVAILABLE FACILITIES SHOWN ON FACTORY
To control and to minimize the various hazards, various facilities are available in the factory and the same is shown on the factory layout plan. The same is given in the Annexure – 2.
Some of the facilities are listed below:
(a) Entry and exit gates.
(b) Boundary wall.
(c) Situation of various departments.
(d) Emergency control center.
(e) Situation of fire extinguishers, storage of fire extinguishers.
(f) First Aid centers.
(g) Process area
(h) Storage area for raw material and bonded storage area for hazardous chemicals (i) Storage of finished products.
(k) Situation of Siren.
(l) Administrative block.
(m) Assembly point.
The factory lay out plan is kept in Security office/EMERGENCY CONTROL CENTRE so that the concerned authority can take proper and immediate action.
2.2 OTHER FACILITIES SHOWN IN THE KEY PLAN
The Annexure – 2 gives the idea of surrounding vicinity and emergency time facilities such as:
(1) Surrounding area, population, and residential premises.
(2) Factory location.
(3) Approaches to the factory.
(4) Hospital, nursing home (5) Fire station (6) Police station (7) Railway/bus stand (8) Mutual aid center.
(9) North direction, wind direction, wind velocity, etc. This key plan is also kept in the Emergency Control Center so that proper and immediate action can be taken by the concerned authority.
2.3 STORAGE HAZARDS AND CONTROLS
In Factory lay out plan, we have shown the place where the raw materials including hazardous substances are stored.
The complete details regarding hazardous raw material, are given in the enclosed Annexure No. 4. Where as the complete details regarding material identification, their use, hazardous ingredients of material, physical data for material, fire and explosion hazard of material, reactivity data, toxicological properties of material, personal protective method and first aid measures is given in the enclosed Annexure – 5 (MSDS).
Release of explosive and flammable chemicals and may create emergency if proper
2.4 ABOUT VARIOUS CATEGORIES OF HAZARDS
The storage hazards can be divided in following three different categories:
(a) Fire hazards
(b) Spillage of chemicals.
(c) Toxic release
Above hazards should be taken into consideration because some of the chemicals used, stored are having flammable, and toxic & corrosive properties.
Now we will describe about each hazards in details.
2.4.1 FIRE HAZARDS
In our factory the most common hazard is of fire. In our factory EDC and Pyridine are stored/ used which is flammable, and can cause dangerous Fire hazards and in spite of all precautionary measures, risk cannot be avoided. Hence, substance that is susceptible to fire and explosion is stored separately at the distance to stop the fire developing with other area methanol is stored separately and storage is approved by controller of explosives.
The fire may take place because of any one or more of the following reasons;
(a) Naked flame (b) Hot surfaces (c) Leakage, spillage (d) Electric spark (e) Static electricity
(f) Rise in temperature & pressure beyond permissible limit.
TO CONTROL THE FIRE HAZARDS, FOLLOWING ACTIONS ARE TAKEN
It is very important for the factory to take all possible steps to pre-empt a fire whenever it can occur and thus avert the possible disaster. In our factory several precautionary measures has been taken to prevent a fire and to fight it promptly and extinguish it even if a fire does occur in any part of the factory. The important measures are out lined below
(a) Naked flames, hot surfaces and other ignition sources should be eliminated from
(b) Flammable chemicals stored with all recommended storage and handling practices.
(c) Storage and process areas are posted with “No Smoking” signs. Smoking is prohibited throughout the factory. All management staff, Executives on their rounds to factory ensures the compliance.
(d) Protective equipments are for use during transferring operations.
(e) Flameproof and short circuit proof electrical fittings will be provided in EDC and Pyridine Storage and Process area.
(f) While unloading Flammable chemicals electrostatic spark is avoided. Earthing of all storage tanks and all electrical installation have been carried out
(g) All required personal protective equipments are kept in every plant and provided to workers working in hazardous area.
(h) Sufficient amount of water and bore wells available in the factory to put out the fire of other origin. Two under ground water tank of capacity 10,000 liters capacity each are kept.
(i) EDC and Pyridine Methanol is pumped in closed pipeline.
(j) On site emergency plan is prepared.
2.4.2 LEAKAGE & SPILLAGE HAZARD OF CHEMICAL
The second major hazard is leakage or spillage of toxic chemical. These chemicals cause chemical burns. As storage and transport of liquid chemicals are carried out in closed system there is ordinarily no chance of any splashing of chemical.
TO CONTROL THE SPILLAGE HAZARD, FOLLOWING ACTIONS ARE TAKEN
(a) All Storage tanks are under ground provided with dike wall & sand filling (b) All liquid chemicals are stored in tank or drum.
(c) Pegs and clamps are provided to empty out any tank having uncontrollable leakage.
(d) Spare tanks & barrels of sufficient quantity kept ready (e) .Liquid chemicals are transferred by closed pipeline.
(f) The pipe lines are painted with different colors to distinguish it..
(g) Leak pans will be provided for collecting leakage, if any.
(h) Out going effluent will have to be blocked and taken to effluent treatment plant. It will be discharged after treatment only. Continuous neutralization will also be arranged.
2.4.3 TOXIC RELEASE HAZARD
Ice Make Refrigeration Pvt.Ltd. is a middle scale factory where another hazard is of toxic release MDI , Polyol is used which is Toxic and can cause Toxic hazards. In spite
of all precautionary measures, risk can not be avoided.
The toxic release may take place because of any one or more of the following reasons;
(a) Gas leakage from pipe joint (b) Gas release from safety valve (c) Gas leakage from vent
(d) Rise in temp. & pressure beyond permissible limit (e) Liquid spillage
TO CONTROL THE TOXIC HAZARDS, FOLLOWING ACTIONS ARE TAKEN
It is very important for the factory to take all possible steps to pre-empt a toxic release whenever it can occur and thus avert the possible disaster. In our factory several precautionary measures has been taken to prevent a toxic release and to fight it promptly and control it even if a toxic release does occur in any part of the factory. The important measures are out lined below.
(a) All pipe joints are provided with heavy duty champion gaskets to prevent any leakage (b) MDI , Polyol and approachable place.
(c) Protective equipments are for use during transferring operations.
(d) All required personal protective equipments are kept in every plant and provided to workers working in hazardous area.
(e) Self breathing apparatus will be provided and workers will be trained about their use.
(f) Workers are trained to control any kind of leakage.
(g) On site emergency plan is prepared.
2.4 PROCESS HAZARDS (Annexure-6) (1) Toxic Release
(2) Fire
2.5 CONTROL MEASURES PROVIDED
Looking to the nature of materials processed normal temperature and pressure involved, wide range of characteristics of processes and nature of operations, following process controls and interlocks have been employed.
(a) Procedures and actions have been well defined and know to all operating personnel for safe start up and shut down of plant.
(b) Fire extinguisher and sand buckets are also installed in the plant area.
(c) All the motors and other machines are provided with safety guards.
(d) All exposed parts of moving machineries are provided with suitable guards for personnel safety.
(e) All elevated structures are protected with lightening arrestors.
(f) Insulation of piping as per requirement is provided.
(g) Regarding all components of the plant proper certificates are taken. Also testing and inspection shall not be compromised before deliveries.
(h) All procedures are well defined and standardized with safety angle.
(j) Temp.controlled by thermostat.
(l) Emergency power supply from D.G. set.
2.5.1 OPERATIONAL SAFETY :
(1) Hand gloves, safety goggles, dust mask, helmets, self-breathing apparatus, safety shoes etc. safety appliances are provided to workers.
(2) First – Aid kit is kept available in Emergency control center.
(3) Non destructive thickness measurements are carried out to prevent sudden bursting by thinning out of metal by erosion or corrosion.
(4) Preventive maintenance to avoid failure is carried out. External inspection of piping and testing of lifting tackles cranes etc. is bearing done at regular interval.
2.6 LEAKAGES: CONTROLS
Depending on the leaking rate / source etc., the Following actions will be taken:
(a) Isolation / Cutting of supply of the leaking point transfer to some other vessels / equipments using protective appliances like hand gloves, gum boots, gas mask, PVC suits, etc.
(b) Dilution / Flushing with large quantities of water, fumes / vapors will be knocked down with large quantities of water.
(c) If leakage is from tank / road tanker, attempts will be made to transfer the content of the tank road tanker to some other suitable spare tank as in case of toxic chemicals.
(d) Out going effluent will have to be blocked and taken to effluent treatment plant. It will be discharged after treatment only. Continuous neutralization will also be arranged.
2.7 OTHER HAZARDS AND CONTROLS (Annexure-7)
In our factory, in addition to the storage hazards, process hazards and vessel hazards there are few more hazards which are possible:
(a) Hazards due to electric short circuit.
(b) Fall Accident (c) Natural calamity (d) Bad housekeeping (e) Structural collapse.
2.7.1: HAZARDS DUE TO ELECTRIC SHORT CIRCUIT
Electric short circuit is possible because of any one or more of the following reasons : (a) Loose wiring.
(b) Faulty equipment.
(d) Choking (e) Overheating.
Proper earthing, periodical checking of contacts, proper insulation of equipment, flame proof fitting in solvent area, electrician to be provided
2.7.1 Fall Accident
Falling from height is possible any where in the plant when workman is working at height without safety belt.
Safety belt, helmet, safety platform will be provided at the time of work supervised.
2.7.2 Natural Disaster
Earth quake, lightening, structure collapse, accidental gas release from neighboring unit is possible natural disaster
Lightening arrester, fire fighting equipment and PPEs make ready, mutual aid, on site / off-site emergency plan to be activated
2.7.3 Bad house keeping
Minor or major injury is possible due to bad house keeping.
Proper handling, regular cleaning, proper placement of material will be observed in plant.
2.7.4 HAZARDS DUE TO STRUCTURAL COLLAPSE:
Structural collapse is possible because of any one or more of the following reasons:
(a) Corrosion.
(b) Old structure.
(c) Heavy load.
(d) Extensive vibration.
(e) Heavy stress on structure.
To avoid the above, regular checking will be done by a competent authority in above case, if major emergency may arise suddenly, the outside emergency services can be utilized.
2.8 RECORDS OF PAST INCIDENTS (NO PAST MAJOR INCIDENT)
2.8.1 ABOUT RISK ASSESSMENT PLAN
The risk assessment can be broadly divided in the following heads:
(a) Identification of hazards.
(b) Causes of hazards.
(c) The measures for reducing the hazards.
(d) Hazard operability study.
Considering the above, now we will study about the details regarding various hazards available in our factory.
2.8.2 IDENTIFICATION OF HAZARDS OF FACTORY
The following three are the main hazards in our factory.
(a) Fire hazards
(b) Spillage of chemicals.
(c) Toxic release
More details about above all hazards are given in previous points of this report.
Probability or frequency of above hazards will give details regarding risks involved and analysis of the same will give details regarding how they could occur. The estimation of the extend, magnitude and likelihood of any harmful effects or consequences will give details regarding risk analysis.
2.9 LIMITATIONS OF RISK ASSESSMENT PLAN
The risk assessment study has following limitations.-
(a) Non-availability of norms for our Country.
(b) Non-availability of correct analysis data.
(c) High cost for getting expertise from foreign developed Countries.
(d) Lack of expertise in our Country.
(e) Difficulty of checking the final results with experiments.
(f) Non-availability of past accident data about damages.
(g) Complexity and laboriousness of the techniques.
2.10 VARIOUS METHODS AVAILABLE FOR RISK ASSESSMENT
Various methods are available for the risk assessment. We are giving hereunder a method to identify the potential hazards and operability problems that foreseen by studying the logic of operation.
(a) To define a process sequence.
(b) To apply a guide word.
(c) To generate a deviation.
(d) To found out probable causes.
(e) To derive possible consequences.
(f) To evaluate need for action.
CHAPTER-3
EMERGENCY ORGANIZATION
3.0 No plan will succeed without effective organization. Emergency Organization is the heart of On-site and Off-site Emergency plan. Due weightage has been given to select and assign suitable responsibilities to the most appropriate person from the respective departments in our factory.
Due care has been exercised to earmark the emergency duties from day to day responsibilities. The emergency organization shall prove effective, if activities are carried out in a defined way. To get the maximum advantage of the emergency organization, we have defined the activities of various officers / workers in the following manner.
3.1 INCIDENT CONTROLLER (IC)
Primary duty of incident controller is to take charge at the scene of the incident. In the initial stages he may be required to take decisions involving the operation of the other plants or to stop or continue any process and to take technical decisions to control the incident. Therefore he should have full knowledge for these purposes. For our purpose, General Manager - Operations is appointed as Incident Controller. In the absence of Incident Controller the next person either production in charge or shift chemist whoever present, will be Incident Controller.
3.1.1 THE RESPONSIBILITIES OF INCIDENT CONTROLLER DURING ON SITE EMERGENCY
Being received the primary information from runner about the occurrence, Incident Controller will access the situation and he will try to control the emergency by internal resources. If the situation seen is uncontrollable, he will consult S.M.C. to declare emergency and will sound the siren to announce emergency in the factory as well as ask for mutual aid from surroundings. Further declaring off-site emergency, He will also inform the fire brigade, police, Dist. Disaster Controller and Factory Inspector.
He will arrange for safety equipments and tools for the member of rescue teams.
He will evacuate non essential workers near Assembly point.
He will search for causalities.
He will call all key personnel, essential workers and allot them duties.
3.2 DEPUTY INCIDENT CONTROLLER
One officer in each shift has been identified as Dy. IC, he will assist Incident Controller and will help in mobilizing the required gadgets.
Dy.-Incident Controller will carry out internal communication and will confirm with other service department about their actions and he will co-ordinate between Incident Controller and Site Main Controller (S.M.C.).
Their functions are mentioned in Annexure 33. Their name, designation, place of availability, etc. are given in Annexure 16.
In case of non-availability of both Incident Controller and Deputy Incident Controller We have appointed other substitute persons to take the charge of I.C. and Dy. I.C. their details are given in Annexure 15.
3.2.1 RESPONSIBILITIES OF DY. INCIDENT CONTROLLER DURING ON SITE AND OFF SITE EMERGENCY
In absence of Incident Controller, Dy. Incident Controller will take charge of I.C. and will work in the same line as that I.C. the duties and responsibilities of Dy. I.C. during on- site and off-site will remain the same as given in Point No. 3.4.4 and 3.5 of this plan.
3.3 SITE MAIN CONTROLLER (S.M.C.)
He has overall responsibility for directing operations and calling outside help from Emergency Control Center. As he is required to take decision by collaboration between the senior managers at the site (works) and the senior officers of the outside services, the top executive (C.E.O.) is appointed as site main controller
The moment, the message is received site main controller. are supposed to reach the plant site either with their vehicle or with alternate transport arrangement without wasting a single minute.
Their duties / functions in emergency are mentioned in details in Annexure 33, name, designation, place of availability, etc. is given in Annexure 16.
3.3.1 RESPONSIBILITIES OF SITE MAIN CONTROLLER. DURING ON-SITE AND OFF- SITE EMERGENCY
(a) Declare emergency.
(b) Get it touch with the District Authority or its nominees to take over the control of the emergency.
(c) Inform mutual aid facilities and seek their help if they have the required facilities.
(d) Call Incident Controller and ask him to proceed with the work of controlling the incident.
(e) Inform fire brigade if help is required.
(f) Inform factory medical officer and hospital authority.
(g) Ask the security to account for personnel.
(h) Arrange to get ambulances to send injured workers to hospitals, in case of causality.
(i) Nominate a person to give information to the media public, and members of families of the affected area.
(j) Arrange for admission of the injured workers and affected public to the hospitals.
(k) Find out how many members of the public are likely to be affected.
(l) Arrange through police to warn the public and advise the public regarding the precautions to be taken.
(m) Advise the police to evacuate people from the localities likely to the affected.
(n) Arrange alternate shelter and food for the evacuated public and workers.
(o) Inform police and advise them to control traffic law and order. Also ask them to help in taking injured to hospitals.
(p) Take the help of outside experts, if necessary.
(q) Inform the factory inspector and G.P.C.B.
(r) Remain in touch with the Incident Controller and keep the public informed about the status of emergency.
(s) Assemble the pre-decided team of workers to assist to perform the above functions.
(t) Advise the services like water, electricity, etc. if these have to be cut of resumed for safety of the public.
(u) Give ‘all clear’ signal after the emergency has come under complete control.
(v) Arrange to send the evacuated workers and public back to their homes and assist them to resettle.
(w) If services have been cut off, inform the concerned services to restart after the emergency is controlled
3.4 RUNNER’S AND THEIR RESPONSIBILITIES DURING ON-SITE AND OFF-SITE EMERGENCY.
The entire runner’s of Site Main Controller, Incident controller and Dy. Incident Controller are to remain alert all the time on receiving the message about any emergency. After receiving the massage, it will be the duty of runner to rush to security office or to incident controller.
3.5 KEY PERSONNEL
In the light of information received on the developing situation at the emergency, key personnel will take directive from Site Main Controllers to control emergency in the respective fields.
We will nominate, Key Persons to handle the situation of emergency person wise.
Annexure 17 gives complete detail of persons and their duties in normal and abnormal situation. In case of unavailability of these persons next person will also be nominated. In the emergency instruction booklet, we have added their duties person wise.
3.5.1 RESPONSIBILITIES OF KEY PERSONNEL DURING ON-SITE & OFF-SITE EMERGENCY
(a) The communication will be established by telephone or by sending person with special message by available vehicle
(b) When grave emergency is declared, all the workers will have to leave their work and to reach at safe place knowing the wind direction indicated by the flag hosted at the highest place and as per announcement the plant will be shut down, workers will gather near the assembly point.
(c) We will select a team of workers in each shift and they will take roll call of workers and remove the affected workers to safe place and will provide the medical help which will be kept ready by Incident Controller by summoning the doctor as soon as the emergency is declared.
(d) Counting of workers take place immediately at gate and compared with those present.
(e) Injured workers to be shifted to hospital, if required with the help of police. Lists of hospital, ambulances are kept in the office, as well as with security office near the gate.
(f) Arrangement will be made by the Incident Controller / Site Main controller to inform the relatives of injured workers and Liaison will be maintained with fire brigade and police about the extent of likely spread of gas / fire.
3.6 ESSENTIAL WORKERS
Workers those are trained for fire fighting and first aid are selected as essential workers.
Essential workers are identified and listed in emergency plan.
Many more employees will be trained for the fire fighting and first aid in each group. So their services can be utilized, if required. Their list will be available in Emergency Control Center (E.C.C.).
Identified essential workers are supposed to report at “EMERGENCY SIGHT” to take instruction from Incident Controller. Details of their functions are mentioned in Annexure 33.
3.7 RESPONSIBILITIES OF FACTORY MEDICAL OFFICER
(a) Send assistant to the place where evacuated workers are reporting.
(b) Ensure that those requiring medical assistance are separated.
(c) Treat all those who can be treated within the factory.
(d) Get in touch with Doctors of different hospitals and inform them the nature of injuries etc.
(e) Inform out side hospitals about antidotes and their availability / supplier etc.
(f) Supply antidotes to out side hospitals, if not available and are required by them.
3.8 ASSEMBLY POINTS
Open space near security gate is decided as Assembly Point because, 1. It is away from the process plant.
2. It has separate approaches.
3. Open space is adequate enough to assemble even at one point.
Looking to the wind direction and emergency site, the assembly point is selected at security gate, as there are separate approaches available in case of evacuation; vehicle entry is available on the very spot. Details of assembly point are given in Annexure 19.
3.9 EMERGENCY CONTROL CENTRE
Administrative office/Security office will be declared as Emergency Control Center, Location of E.C.C. is away from the place hence it is considered as an ideal one.
Telephone and other facilities required with required documents are well displayed near the emergency control center for ready reference, Site Main Controller will operate from
Emergency Control Center, and details regarding Emergency Control Center are given in Annexure 20.
3.10 FIRE AND TOXICITY ARRANGEMENTS
Adequate fire fighting equipments and personal protective equipments will be available in factory premises. Portable fire extinguishers will be installed at various locations in plant and will be easily accessible too. They will be regularly inspected for their working conditions. In the same fashion, all personal protective appliances will be maintained in good working condition so the same can be utilized in emergency.
Essential workers and other personnel will be regularly trained to use both fire fighting and personal protective equipments. Details of such information are given in Annexure 21 (A, B, C).
3.11 MEDICAL ARRANGEMENTS
First Aid boxes will be provided in every department. These boxes equipped with all required first aid facilities like bandages, antidotes, antiseptics to deal with minor injuries and to help in major exposure, until the victim is transferred to the hospital or until the doctor arrives.
First Aid box will be in charge of trained person. A stand by emergency vehicle is always kept if victims are required to be transferred to outside hospitals. Telephone numbers of nearby factories are also available, if ambulances are required at a short notice. FMO is also available on call.
Moreover, efforts will be put to train essential workers and other employees to give first aid. Details of such information are given in Annexure 22 (A, B).
3.12 TRANSPORT / EVACUATION ARRANGEMENT
After declaring the emergency depending on the situation
(1) Non-essential persons like casual contract labourers, other non required company workers, will be evacuated to pre-determined safe assembly points or outside the factory depending on the severity. There are no. of safe assembly points which may be utilized depending on the wind direction, distance from the incident.
(2) People residing outside the Company and at close distances, will be requested to evacuate. They will be evacuated and transported to safe places / shelters.
(3) Help of Police, Civil Authorities etc. will be taken for evacuating outside people.
(4) Personnel required to be transported to medical care, will be transported to hospital by ambulance or vehicle available.
(5) SMC along with respective key personnel will arrange for such activities including rescue and transportation of injured persons, casualties etc.
(6) Transportation arrangements will have to be made for people / essential workers / experts / key personnel to be brought from their houses
3.13 USE OF EXTERNAL AUTHORITIES
(1) Experts on safety, health, pollution control special technologist will be contacted and their skills will be utilized. A list of such experts should be kept ready with phone numbers, mobile numbers, etc. so that at the time of emergency they can be available easily.
(2) Police, District Collector, Factory Inspector, Controller of Explosive, Pollution Control Board Experts, Health and Medical Officer etc. will be contacted and called in for help.
(3) R&B Civil Engineers also can be contacted for specialized activities like temporary shelter requirements, digging work, provision of facilities in Public Building etc.
(4) Help of Institution, Social Organizations, Corporation, and Voluntary Bodies etc.
will be taken as per need. A list of such organization will be kept ready with telephones. Communication in normal times will help speedy response.
CHAPTER-4
COMMUNICATION SYSTEM
4.0 we have gone through the details regarding the assessment of risks and their possible environmental impact till now. To deal with the any hazardous situation, we have to make communication system up-to-date and ready in all respect.
The efficient communication is a very crucial factor in handling an emergency. The emergency organization will prove worth only if the communication system operates effectively and in time / everything will be paralyzed,
The communication system beginning with raising the alarm (siren) declaring the major emergency and procedure to make it known to others is given hereunder.
4.1 RAISING THE ALARM
Any employees of our company noticing an emergency will raise the alarm (siren).
Essential workers will act as messengers for spreading the emergency position.
4.2 EXTERNAL TELEPHONE(Annexure 28)
(a) All-important EXTERNAL TELEPHONE NUMBERS are listed in Annexure 28.
(b) It is very essential to have a complete list of external telephone to communicate with the following in case of any emergency.
1. Key personnel residing outside the township.
2. Mutual Aid facilities, hospitals, ambulances, fire brigades, transports etc.
3. Authorities like Dist. Collector, DSP, SRP, Home guards etc.
4. Inspector of Factories / Dept. of Explosives, Electrical inspector, Boiler inspector etc.
4.3 DECLARING THE MAJOR EMERGENCY (Annexure 29)
Once the incident has been noticed by somebody in the plant shift in charge / operator will be informed immediately. He will act as incident controller (IC) to control the emergency simultaneously. Other plant control rooms will be informed immediately as per priority and requirements.
(a) Occupier and other staff etc. will be informed immediately.
(b) Fire and safety key personnel, maintenance key personnel and other key personnel will also be informed at the earliest possible.
(c) Now to decide whether the emergency is a major or not, is very important. We have to declare it at the earliest, making the necessary judgment of the incident for any major emergency or potential for the same. Care will have to be taken so that immature judgment does not occur and inadequate thought is not given as declaration of major emergency puts many agencies into action.
(d) We have nominated persons to declare the major emergency at the earliest with adequate judgment. There may be joint decision also but it must be without wasting the time
4.4 TELEPHONE MESSAGES
After knowing the emergency and emergency declaration or on receiving the emergency message on telephone, They should be precise, sharp, attentive and quick in receiving and noting the message and then for immediate subsequent action of further communication.
The complete details of the instruction in the event of declaration of emergency are given in Annexure No. 33.
4.5 COMMUNICATION OF EMERGENCY
The state of emergency has to be communicated to the following group of people.
(a) Inside the factory to the workers including key personnel and essential workers, who are on duty and or inside the factory premises during normal working hours.
(b) To the key personnel and essential workers who are not on duty and are outside the factory premises besides the normal working hours.
(c) To the outside emergency services including Government Authorities, (d) To the neighboring firms and the general public in the vicinity.
Now we are giving details regarding the system which we have planned the effective implementation for the above.
4.5.1 INSIDE THE FACTORY TO THE WORKERS
To handle the emergency safely and timely, all following information are made known to the workers in the shade of booklet so that they prepare themselves to prevent or to control the emergency.
(a) Safety manual and booklets.
(b) Hazards involved in the process.
(c) MSDS of all the hazardous chemicals used by us.
(d) Various physical and health hazard.
(e) Various measure to ensure safety and control of physical and health hazard.
(f) Various measure to be taken by the workers to ensure the safe handling, storage and transportation of hazardous chemicals.
(g) Various personal protective equipments available for handling hazardous chemicals.
(h) Messaging of various label and marking on containers of hazardous chemical.
(i) Measures to be taken by the workers in case of spillage or leakage of hazardous chemicals.
(j) Worker’s role in emergency.
4.5.2 KEY PERSONNEL AND ESSENTIAL WORKERS
Key personnel and essential workers are available in all shifts or can be made available with short notice.
But due to some reasons, if they are outside or not on duty and if their help is required, their where about is available in the Annexure 14 to 18 which are kept in the emergency control center. List of the name in order of priority is kept near telephone junction.
4.5.3 OUTSIDE EMERGENCY SERVICES & AUTHORITY
Once the declaration of emergency is made, we have planned to inform the following services immediately.
(a) Fire Brigade (b) Police station (c) ESI hospital
(e) Civil defense
(f) Hospital / Private Nursing home (g) Key personal of mutual aid scheme (h) Pollution control board
(i) Factory Inspector, Regional Collector, (j) District Collector.
(k) Municipality
(l) Press, Radio and TV
The phone numbers with concerned person for the above agencies are available near telephone
