EPRP

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EMERGENCY PREPAEDNESS
AND RESPONSE PLAN
Name of Employee
Designation
Signature
Date
Prepared By:
Reviewed by :
Approved by:
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TABLE OF CONTENTS
S. No
Description
Page. No
1.
Preface
2.
Introduction
3.Tt The Concept
8-9
4.
Objectives of the Emergency plan
5.
Environment, Health & Safety (EHS) Policy
10
6.
Definition of an Emergency
10
7.
Brief Description of the plant
10-11
8.
Key Personnel at the Factory
11
9.
Minimum number of persons working in each shift
10.
Hazardous Chemicals at site :
11-12
12
i.
Warehouse-I
12-13
ii.
Warehouse-II
14
iii.
Solvent Tank Farm Area
14-15
11.
Process Description
15
12.
Main Products Manufactured
15-16
13.
Approach Roads
16-17
14.
Metrological Information: Predominant Wind direction
17
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15.
Emergency Power Supply
16.
Emergency Control Center (ECC)
17.
Assembly Points
18
18.
First Aid and Medical Facilities
18
19.
Medical Examination of the Employees
19
20.
Ambulance Availability in case of Emergency
19
21.
Communicating the Emergency inside the Factory

Premises
22.
Communication with Local Services
23.
Escape routes - For Evacuation
20-21
24.
Safety Showers and Body Washers
21-22
25.
Identified Emergencies at Site
22
26.
Categorization of Emergencies
22-24
27.
Noticing of Fire/ Explosion or Toxic Release Emergency
24-25
28.
Declaration of Emergency
25
29.
Emergency in Night Time
25-26
30.
Centralized Electrical Siren
26
31.
Controlling the Emergency
26-27
32.
Fire Prevention / Protection Measures
33.
Plant layout and facilities
27-28
34.
General Instructions for During an Emergency
28-29
35.
Organization Chart in Emergency
36.
Incident Notice
37.
Emergency Coordination Team
34
38.
Responsibilities During Emergencies :
35
i) Site Controller
17
17-18
19-20
20
27
29
30-33
35
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ii) Incident Controller
36
iii)
Block / Section In charges
36
iv)
Safety & Evacuation Coordinator
v) Medical Coordinator
vi)
Communications Coordinator
36-37
37
37
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vii)
Fire Coordinator
37
viii)
Shut Down & Leak Control Coordinator
37
ix)
Security Coordinator
38
x)
Supervisor/ Officer of the Affected Area /Block
38
xi)
Executive - All Departments
38
xii)
Shift Electrician/Supervisor
38
xiii)
Ambulance Driver
39
xiv)
Manager Administration
39
xv)
All Other Employees
39
39.
Potential Emergency Situations at site
40
40.
Environmental Emergencies
41
41.
Spillage of Hazardous Chemicals & Wastes
41
42.
Emergency Procedure for Fire & Explosion
41-42
43.
Fire and Explosion Emergency in Solvent Tank Farm Area
42-43
i.
ii.
44.
Solvent Storage Pool Fire Damage Caused at Different Incident

levels of Thermal Radiation
Solvent Storage Pool Fire - Typical value and their Associated
damage levels of Thermal Radiation
43
43
iii.
Solvent storage pool fire: Results of Thermal Radiation
44
iv.
Solvent storage pool fire: Consequence contour for Methanol

Storage pool fire
44
Detailed Actions for Handling Various Emergencies

i. Action in Tank Farm area during Emergency
44
44
ii. Emergency Procedure for Handling Fire in Solvent Storage tank farm
44-45
iii. Emergency procedure for Handling fire and Explosion in Hydrogen or

Gas leakage
45
iv. Emergency Procedure for Handling fire and Explosion in Reactor
46
v. Emergency Procedure for Handling Fire and Explosion in Centrifuge
46
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vi. Emergency Procedure for Handling Fire and Explosion in Boiler
46
vii.Emergency Procedure for Handling Fire and Explosion at ETP
46-47
viii.Emergency procedure for Handling Fire and Explosion in Diesel

Generator
47
ix. Emergency Procedure for Handling Lithium Aluminium Hydride Fire
47-48
x. Emergency Procedure for Handling Sodium Hydride Fire
48
xi. Emergency Procedure for Handling Sodium Metal Fire
48
xii.Emergency Procedure for Handling Bromine Leak
49
xiii.Emergency Procedure for Handling Chlorine Leak
49-51
xiv.Emergency Procedure for Handling Dry HCL Leak
51-52
xv.Emergency Procedure for Handling Ammonia Leak
52-54
xvi.Emergency Procedure for Handling Acid /Alkalies Leak

xvii.
Emergency Procedure for Handling Chemical Spillages
xviii.
Emergency Procedure for Disposal of Chemical Spillages Outside

the block
xix.Emergency Procedure for Handling Nitrogen Gas leak in Closed Room

xx. Emergency Procedure for Handling LPG Gas Leak in Canteen Area
xxi.Emergency Procedure for LPG gas Fire in Canteen Area
55
55-57
57
57-58
58
58-59
xxii.
Emergency Procedure for Electrical Fire in Panel Room
59
xxiii.
Emergency Procedure for Electrical Fire in MCC Room
59
xxiv.
Emergency Procedure for HT Yard Fire
59
xxv.
Emergency Procedure for Raney Nickel Fire
60
xxvi.
Emergency Procedure in case of Thionyl Chloride Leak
60
xxvii.
xxviii.
Emergency Procedure in case of Solvent Fire

Emergency Procedure in case of Oxalyl Chloride Leak
60
60-61
xxix.
Emergency Procedure in Mg Metal Fire
61
xxx.
Emergency Procedure in case of Tri phosgene Leak
61
xxxi.
Emergency Procedure in case of Titanium Tetra Chloride Leak
61
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xxxii.
Emergency Procedure in Spillage of Caustic Soda Lye
61-62
xxxiii.
Emergency Procedure in Spillage of ATFD Hot Material
62
xxxiv.
Emergency Procedure Fire in HVD (high vacuum distillation)
62
xxxv.
xxxvi.
Emergency Procedure in case of Scrubber Failure

Emergency Procedure in Boiler and Coal Storage Area
62
62
xxxvii.
Emergency Procedure for Fire in Thermic Fluid Heater
63
xxxviii.
Emergency Procedure in Hazardous Waste Storage
63
xxxix.
Emergency Procedure in Hazardous Material Transportation
63
xl.Emergency Procedure in case of Flooding and Cyclone
63
xli.Emergency Procedure in case of Earthquake
64
xlii.Emergency Procedure in case of Lightning and Thunder
64-65
xliii.
Emergency Procedure in case of Cyanide Poisoning
65-66
xliv.
Emergency Procedure in case of Food Poisoning
67
45.
End of the Emergency: All Clear Siren
67-68
46.
Evacuation Procedure
68-69
47.
Communication Procedure during Emergency
48.
Recovery Process Plan
49.
Mutual Aid Procedure in Major Emergency Situation
71
50.
Details about the Mutual Aid Industries with Phone Numbers
72
51.
Internal Telephone Numbers
73-74
52.
External Agencies Telephone Numbers
75-76
53.
Key Personal Contact Number
76
54.
List of First Aiders
77
55.
List of Fire Fighters
78
56.
Fire Hydrant Pump Details
79
57.
Fire Hydrant Details: Emergency Equipments Available at Site
69
70-71
79-80
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58.
Location Wise Portable Fire Extinguishers
81-82
59.
List of Abbreviations
83
60.
Site Layout Plan
--
61.
Fire Hydrant Line Layout
--
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PREFACE:
A Totally safe chemical plant could exist only in theory. The best available design of plants and
procedures notwithstanding there is in practice, always a certain probability of circumstances
combining to make things go wrong, the unexpected to happen and an accident to occur and an
emergency can occur in any chemical industry. Numerous instances are known, whereby timely and
effective action after the event, has greatly contributed towards minimizing the damage to plant and
property and loss of lives.
Chemical industries have an onerous responsibility to preserve and protect the environment and ensure
that whatever happens within their premises does not affect the surrounds.
With the above in view, an Onsite Emergency Control Plan has been prepared for our factory at
Mekaguda. All concerned are hereby requested to carefully study and thoroughly familiarize themselves
with it, in order to ensure its effective use in times of emergency.
It is sincerely hoped that his Emergency Preparedness & Response Plan will help all NPCD
employees to prepare themselves to contain, control, mitigate, and neutralize the consequences of any
emergency that may arise.
INTRODUCTION:
xxxx PHARMA LIMITED, Chemical Division (NPCD) at Mekaguda Village, Kothur Mandal,
Mahaboob Nagar District, and Andhra Pradesh has taken steps to assess, minimize and wherever
feasible eliminate risks. In spite of its best efforts, an emergency may still occur which may affect life
and property within the plant and its neighborhood. Therefore, an Onsite Emergency Plan has been
prepared for mitigating the effects of a major emergency.
In the interest of all the employees this plan should be put into practice during an emergency. Mock
drills and rehearsals are conducted periodically to ensure preparedness of all the concerned for effective
implementation of the plan. The Onsite Emergency Plan will be upgraded as and when there are
changes in the facilities.
The success of this plan in accomplishing its purpose depends largely upon each individual carrying out
his/her designated duties effectively and promptly.
THE CONCEPT:
Emergency in Plant Parlance is fire, explosion and toxic release and has the potential to cause serious
injury/loss of life and damage to property and which tends to cause disruption inside and sometimes
extends outside the plant. Emergency could also set- in due to external situations like natural calamities,
sabotage etc.
It is the preparedness of the plant that differentiates the impact. Almost all emergencies start from small
events and lead to emergency and then to disaster. It is the response in the first five minutes that makes
an event small or big. This can happen only if exigencies have been identified and procedures properly
planned, practiced, evaluated and improved.
The Emergency plan is a statutory requirement as per provision of sub section 4B of the Factories
(Amendment) Act, 1987. The purpose of this on-site emergency plan is to ensure the life and
properties of all concerned and minimize the damage to the maximum possible extent, in case of any
emergency.
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Preparation of Onsite Emergency Plan is mandatory under Rule 13 of Manufacture, Storage and
Handling of Hazardous Chemicals, 1989. Schedule 11 under Rule 13.1 of Manufacture, Storage and
Handling of Hazardous Chemical provide guidelines for preparation of onsite Emergency Plan. Based
on the concepts and guidelines provided, an action plan indicating clearly, the duties to be performed by
different persons in the factory during an emergency is laid down in the form `On site Emergency
Plan.
This " ON-SITE EMERGENCY MANAGEMENT PLAN has been prepared to outline the response
of the Management to control emergencies in the M/S. XXXX PHARMA LIMITED, MEKAGUDA.
This plan will explains basic requirements, definitions, objectives, manufacturing process and plant
facility details as called for under schedule 13 of Manufacture, storage and handling of hazardous
chemicals. This includes key elements, organization chart, roles and responsibilities, hazard analysis
details, possible emergencies, contents of emergency control centre etc.
OBJECTIVES OF THE EMERGENCY PLAN:
To define the hazards and assess the risks and identify the Maximum Credible Loss Scenario
(MCLS)
To outline the responsibilities and functions of the key members of the emergency response team, to
Safeguard other employees and environment.
To inform authorities and mutual aid centers to come for help.
To effect rescue and treatment of casualties. To count injured.
To identify and list any fatal accident.
To inform and help relatives.
To secure the safe rehabilitation of affected areas and to restore normalcy.
To preserve records, equipments etc., and to organize investigation into the cause of the emergency
and preventive measure to stop its recurrence.
Purpose of the plan: This plan is developed to:
Control or limit any effect arising out of an emergency or potential emergency that may arise at the
plant.
Formation of emergency response team and provide assistance at the plant.
To ensure communication of all vital information to appropriate internal and external bodies as
soon as possible.
To facilitate reorganization activities so that operations can be resumed.
To provide training so that an appropriate level of preparedness can be continually maintained.
To provide a basis for updating and reviewing emergency procedures.

Scope of the plan: The scope of the plan is to ensure safety of life, protection of environment,
protection of the plant facility and restoration of production salvage operations, in these orders of
priorities.
ENVIRONMENT, HEALTH & SAFETY (EHS) POLICY:

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We XXXX PHARMA LIMITED Chemical Division situated at Mekaguda, Mahaboob Nagar

district produce Pharmaceutical Active Ingredients and Intermediates.
We are committed to:
Comply with applicable legislations, regulations and other applicable requirements.

Incorporating suitable techniques such as waste management, recovery of raw materials, isolating byproducts and distillations of solvents to prevent pollution.
Conserving raw materials, natural resources such as water, coal & electricity.
Reduce the risks by identifying, assessing and controlling the hazards to prevent ill-health and injury.
Continually improve EHS performance by setting time bound objectives and targets.
Promote awareness of EHS requirements among the employee, contractors and visitors.
Continually improve our environmental, health and safety performance.
Communicated to all persons in the organization and made aware of their individual Occupational
Health and Safety obligations.
Date: 29-09-2011
Rev: 03
Chairman and Managing Director
DEFINITION OF AN EMERGENCY:
Emergency means a situation or condition leading to circumstances or set of circumstances in which
there is a danger to life or health of persons or which could result in big fire or explosion to the work
and outside environment affecting the workers or neighborhood in a serious manner, demanding
immediate action.
OR
An emergency occurring in a factory is one that may affect several departments within it and may cause
serious injuries, loss of life, damage to the property and the community beyond the factory premises. It
may require assistance from external agencies such as fire brigade, local hospitals, Road Transport
Authority (RTA), Police, District Emergency Authority (DEA) etc. to manage it effectively.
BRIEF DESCRIPTION OF THE PLANT:
S.N
O
Name of the Factory

Factory Address
XXXX PHARMA LIMITED,

Chemical Division, Mekaguda.
Mekaguda village, Kothur Mandal.
Mahaboob Nagar district
Tel : 08548-249496
Fax : 08548-249491
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Head Office Address with Tel. XXXX HOUSE

No.
Road No: 2, Banjara hills
Hyderabad- 5000033
Tel : 040-23547532
Fax: 040-23548243
Full Name & Address of the Mr. P. Bhaskara Narayana
Occupier:
Director (Finance), XXXX HOUSE, Road
No.2, Banjara Hills, Hyderabad 500 033
Full Name & Address of Plant Mr. PSRK Prasad
Manager:
Executive Vice president- CES
Mekaguda village, Kothur Mandal.
Mahaboob nagar district
Tel : 08548-249496
Mobile : 9866005215
KEY PERSONNEL AT THE FACTORY:

Dr. D. Linga Rao
President - Technical Affairs
Mobile : 9866005214
Mr. P.S.R.K. Prasad
Executive Vice President
Mobile: 9866005215
Mr Prakash Bhavikatti
Dy General Manager- EHS
Mobile :8790560899
Mr CH. Brahma Rao
Dy General Manager- Maintenance
Mobile :9849735219
Mr Venkata Rao
Vice President Production
Mobile :9866005196
Mr. M. Nageswara Rao
Sr. Manager - WH
Mobile:9550240469
Mr N. Satya Narayana
Sr Manager- HRD
Mobile :9949533374
Mr P. Chiranjeevi Rao
Dy General Manager- Environment
Mobile :9848196822
MINIMUM NUMBER OF PERSONS WORKING IN EACH SHIFT:

Total employees are working in around 600 whereas not more than 130 will be available at any given
time. Qualified supervisors are recruited for operation and handling of chemicals. All employees who
are handling hazardous chemicals and supervising are qualified a degree in chemistry or diploma in
chemical Engineering/technology with five years experience. And a master in chemistry or degree in
chemical engineering /technology with two years experience.
Shifts:
1st Shift: 6.00 to 14.00 Hrs
No of employees
110
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2nd Shift: 14.00 to 22.00 Hrs

3rd Shift: 22.00 to 6.00 Hrs
General Shift: 8.45 to 17.15 Hrs
110
110
255
Total
575
Working hours:
A Shift
B Shift
C Shift
General Shift
:
:
:
:
06.00Hrs To 14.00Hrs
14.00Hrs To 22.00 Hrs
22.00Hrs To 06.00Hrs
08.305Hrs To 17.30Hrs
HAZARDOUS CHEMICALS AT SITE:

i )Ware House I:
S.No
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.
16.
17.
18.
19.
20.
21.
22.
23.
24.
25.
26.
27.
28.
29.
30.
Name of the Material

1,4 Dioxane
1,6 Di Bromo Hexane
3-Ethynyl Benzamine
4-Flouro Benzo Nitrile
Acetic Anhydride
Acrylo Nitrile
Ammonia Liquid
Ammonium Chloride
Benzyl Alcohol
Benzyl Amine
Benzyl Chloride
Caustic Soda Flakes
Chloro Acetyl chloride
Di Ethyl carbonate
Dimethyl Sulphate
DMF + DMA
Epi Chloro Hydrine
Ethyl Aceto Acetate
Ethyl Alcohol
Ethyl Bromide
Ethylene Di Amine
Fluoro Benzene
Formaldehyde
Formamide
Formic acid
Formic acid
Hydrogen Peroxide
IPA HCl 10%
Iso Propyl Ether
Isovaleraldehyde
Type of Storage
Drums
Drums
Tins
Tins
Tins
Drums
Drums
Bags
Tins
Carboys
Drums
Bags
Tins
Drums
Drums
Drums
Drums
Drums
Shippers
Drums
Drums
Drums
Carboys
Drums
Drums
Tins
Carboy
Drums
Drums
Drums
Nature of the Material

Flammable&Toxic
Flammable
Flammable
Flammable
Flammable & Corrosive
Flammable &Toxic
Toxic
Toxic
Flammable
Flammable
Toxic& Corrosive
Corrosive
Corrosive
Flammable
Corrosive
Flammable
Flammable &Toxic
Flammable
Flammable
Flammable&Toxic
Flammable
Flammable
Flammable
Flammable
Corrosive
Oxidizing
Flammable& Corrosive
Flammable
Flammable
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31.
32.
33.
34.
35.
36.
37.
38.
39.
40.
41.
42.
43.
44.
45.
46.
47.
48.
49.
50.
51.
52.
53.
54.
55.
56.
57.
58.
59.
60.
61.
Lithium Aluminum Hydride

Lithium Hydroxide
Methane Sulfonic acid
Methane Sulfonyl Chloride
Methyl Chloro Acetate
Methyl Ethyl Ketone
Methyl Iso Butyl Ketone
Methyl Tertiary Butyl Ether
Mono Methyl Amine
n-Butanol
n-Heptane
N-Methyl Benzyl Amine
Para Tolunitrile
Petroleum Ether
Phosphoric acid
Pinacolone
Potassium hydroxide
Pyridine
Pyridine
Secondary Butyl Alcohol
Sodium Azide
Sodium Bromide
Sodium Meta Bio Sulphate
Sodium Methoxide solution
Tertiary Butanol
Tertiary Butyl Aceto Acetate
Tertiary Butyl Acetylene
Tri Ethyl Amine
Tri Methyl amine
Tri Phenyl Phosphine
Tri Phosgene
Tins
Bags
Carboys
Drums
Tins
Drums
Drums
Containers
Drums
Drums
Drums
Carboys
Carboys
Drums
Carboys
Drums
Bags
Drums
Tins
Drums
Box
Carboys
Bags
Drums
Drums
Drum
Drums
Drums
Tins
Drum
Carboys

Flammable
Flammable
Flammable &Toxic
Flammable
Flammable
Flammable
Flammable
Flammable
Flammable
Flammable
Flammable
Flammable
Flammable
Corrosive
Flammable
Toxic & Corrosive
Flammable
Flammable
Flammable
Harmful
Harmful
Flammable
Flammable
Flammable
Flammable
Flammable
Flammable
Flammable
Flammable
Toxic
ii) Ware House II:

S.No
10.
Type of Storage
1-Bromo-3-Chloro Propane
Aceto Nitrile
Benzoic Acid
Copper Cyanide
Dimethyl Amine
Dimethyl Formamide
Dimethyl Sulfoxide
Hydro Bromic acid CP
Magnesium Turnings
Para Bromo Fluoro Benzene
Drums
Drums
Drums
G.I Tins (25 Kg)
Drums
Drums
Drums
Drums
Tins
Drums
Nature of the
Material
Corrosive
Flammable
Flammable
Toxic
Flammable
Flammable
Flammable
Corrosive
Flammable
Flammable
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11.
12.
13.
14.
15.
16.
17.
18.
19.
20.
21.
Phosphorous Pentoxide
Phosphorous Pentoxide
PTS Acid
Raney Nickel
Sodium Boro Hydride
Sodium Cyanide
Sodium Hydride
Solvent Ether
Stannous Chloride
Tetra Hydro Furan
Tri Ethyl Ortho Formate
Containers (25 Kg)

Carboys (25 Kg)
Carbuoys
Container (20 Kg)
Tins (190 Kgs)
Tins
Bags
Drums
Tins
Drums
Drums
Corrosive
Corrosive
Flammable
Flammable
Flammable
Toxic
Flammable
Flammable
Harmful
Flammable
Flammable
iii) Solvent Tank farm area:

S.No
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
Storage Tank No
Capacity
Nature of the Material
ST-801
Ethyl Acetate
20KL
Flammable
ST-802
Acetic Acid
30KL
Corrosive
ST-803/1
Chloroform
30KL
Flammable
ST-804
MCL
30KL
Toxic
ST-805
MCL
30KL
Toxic
ST-806
Diesel
30KL
Flammable
ST-807
Diesel
30KL
Flammable
ST-808
Acetone
30KL
Flammable
ST-809/1
Hexane
30KL
Flammable
ST-810/1
Toluene
30KL
Flammable
ST-811/1
Toluene
30KL
Flammable
ST-812/1
Acetone
19 KL
Flammable
ST-813
Methanol
100KL
Flammable
ST-814
IPA
30KL
Flammable
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15.
16.
17.
18.
ST-815
IPA
20 KL
Toxic
ST 822
Methanol
30 KL
Flammable
ST-835
Hexane
30 KL
Flammable
ST-808/1
Cyclo hexane
30 KL
Flammable
PROCESS DESCRIPTION:
In Production department, Reactors, Centrifuges, Nutsch filters, Leaf filters, Dryers, Millers, Sifters,
Micronizers & Blenders are the main equipments.
Reactors: Reaction shall be carried out in reactors. Different capacity Stainless Steel Reactors and
Glass Lined Reactors are used in Production and selection of reactor is to be done based on the nature
of the chemical. All the reactors will have jacket provision. The contents of the reactors can be heated /
cooled by passing steam / cooling tower water. Based on the process requirement, different type of
stirrers like anchor, propeller, turbine etc will be used with variable RPM. The chemical reactions
carried out in the reactors are mostly distillation, chlorination, nitration, Bromination, Friedel craft
alkylation and hydrogenation.
Centrifuges / Nutch filter: will be used for wet material isolation from reaction mass based on the
material nature.
Leaf filters: Leaf filters are used to remove the activated carbon used in the reaction mass for colour
improvement or to remove the spent sodium sulphate used for moisture removal.
Driers: Isolated wet materials shall be dried using different driers
Multi miller: Dried material shall be milled to de-lump the lumps formed during drying.
Sifters: Sifters are used to control the particle size of the material.
Micronizers: Micronizer is used to reduce the particle size of the API as per customer requirement.
Blenders: Two or more production lots shall be blended to increase the commercial batch size.
MAIN PRODUCTS MANUFACTURED:
S. No.
1
2
3
4
5
6
7
8
Name of the Product

Anastrozole
Citalopram Hydrochloride
Granisetron Hydrochloride
Letrozole
Rizatriptan Benzoate
Salmeterol Xinafoate
Sumatriptan
Tamsulosin Hydrochloride
Block
Kilo Lab
Kilo Lab
Kilo Lab
Kilo Lab
Kilo Lab
Kilo Lab
Kilo Lab
Kilo Lab
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S. No.
Name of the Product
9
Tolterodine tartrate
10
Trihexyphenidyl HCl
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
Block
Kilo Lab
Kilo Lab
Zoledronic Acid
Kilo Lab
Zolmitriptan
Kilo Lab
Paroxetine Hydrochloride Hemihydrate
Pilot Plant
S-Citalopram Oxalate
Pilot Plant
Sumatriptan succinate
Pilot Plant
Terbinafine Hydrochloride
Pilot Plant
Isosorbide- 5-Mononitrate
Production Block-II
Isosorbide Dinitrate
Production Block-II
Citalopram Hydrobromide
Production Block-III
Erlotinib Hydrochloride
Ibandronate sodium monohydrate
Ondansetron Hydrochloride
Imatinib Mesylate
MPB A
Sertraline Hydrochloride
MPB A
Fluoxetine Hydrochloride
MPB B
Lansoprazole
MPB B
Lanthanum Carbonate
MPB B
Omeprazole
MPB B
Pantoprazole sodium
MPB B
Glatiramer Acetate
MPB CK
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APPROACH ROADS:
A well-laid and wide road runs all around all the buildings/production blocks and solvent storage tank
farm area. Two gates are ends of the road lead to the National Highway No. 7, which connects
Hyderabad & Bangalore. The same road leads to Mekaguda village towards North side.
There is one main gate at Security office on East side, one gate on South West Boundary wall the site.
(Gate 1: Main Security-Time office, Gate: 2: checking). The first gate is used for allowing Emergency
Vehicles like Fire Brigade, Ambulance vans etc., to enter. The gate 1 & 2 are manned round the clock
by Security Officer and Security Guards.
Security Setup:
One Security Officer available in General Shift
10-12 Security Guards available in each shift.

Boundaries: Total site have 3 feet compound wall with solar fencing all around.
East Side Inmulnarva to kolbaithanda road

West Side Mekaguda to kondanguda road
North Side Inmulnarva to shadnagar road reaches national high way
South Side Mekaguda to kondanguda road
METROLOGICAL INFORMATION: PREDOMINANT WIND DIRECTION:
Following are the predominant wind direction:
February to April
May to September
October to January
Average Wind Velocity
:
:
:
:
Towards North West & North

Towards North East & East
Towards South West & West
10 Km/Hour
EMERGENCY POWER SUPPLY:

Emergency lights are provided in all the production blocks each floor and raw material stores. 1 no.
1200 KVA, 2 nos each 1000 KVA & 3 nos each 320 KVA for production and utilities back up. Diesel
Generators are also available for providing power supply to the lighting system and the critical
equipment like reactors, fire pumps, effluent treatment plant, scrubbers etc. in case of APSEB power
failure. One no of dedicated diesel operated pump provided for Fire Hydrant System in the Fire Pump
House.
Utilities of Power Sources: HT Connection 750 KVA
Alternate Power Sources: Diesel Generator 1500 KVA
UPS Power ---5 KVA, 10 KVA, Emergency Lighting Circuits.
EMERGENCY CONTROL CENTER (ECC):
Corner of the administration building will be the emergency control center with the following
Provisions / facilities.
Copy of Emergency Preparedness and Response Plan (EPRP).
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Plant layout with escape routes, assembly points clearly marked.

Detailed layout of Fire Hydrant Line.
Emergency Team organization chart.
Master rolls of Employees of all departments.
Emergency trolley with fire extinguishers and other equipments for fire fighting.
Personal protective equipment (PPE) such as fire entry suits, respiratory cartridge masks, selfcontained breathing apparatus (SCBA) Sets, PVC & heat resistant suits, gloves, goggles,
Ear muffs and gum shoes etc.
Material safety data sheets (MSDS) of the chemicals being used in the factory.
Internal telephone, External telephone, and Cell phone for outside contact.
List of important telephone number and addresses of key persons.
List of nearby hospitals / doctors with telephone numbers.
List of nearby fire brigades and their telephone numbers.
List of ERT & First-aid members.
First-aid boxes.
Flame Proof Torch Lights.

Mega Phone for public announcement system.
Note pads, white papers, pens, pencils etc.
ASSEMBLY POINTS:
All employees in the block where the emergency occurs shall evacuate the work place and assemble at
the locations identified as assembly points. Site Plan showing the Evacuation Routes & Assembly Points.
Depending upon the wind direction the following are the assembly points
Assembly point no -1 (Near Canteen & Administration building)

Assembly point no -2 (Near Power house)
Assembly point no -3 ( Near Effluent treatment plan)
FIRST AID AND MEDICAL FACILITIES:
First Aid Boxes are provided at required places.

Occupational Health Centre is provided which is running round the clock with Factory Medical
Officer and qualified Male Nurses. Necessary equipment like cot, bed, stretchers, examination table,
weighing machine, oxygen kit, resuscitator auto clave, suction a machine and required First Aid
items are provided.
An Ambulance Van is available round the clock for transporting injured/sick persons from Factory to
Hospital and from the site of incident to the Occupational Health Centre.
Records of Medical Examination and Treatment are maintained.
Suction machine, Blood Pressure apparatus, Autoclave for sterilisation of dressings & equipment,
antivenom injection etc.
Antidote such as Atropine sulphate & life saving medicines are kept.
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First Aid Training is given to the First Aiders during Safety Training Programmes.
Recognised Hospitals and Eye Specialist at Hyderabad are located at a Distance of 50 km from the
factory.
Government Hospital is available at Hyderabad and nearby Doctors and Hospitals are contacted in
Emergency by our FMO.
Critical Cases are referred to Govt Hospitals/Specialised Hospital at Hyderabad Secunderabad,Bidar
under the guidance our Factory medical Officer
Emergency showers/eye wash fountains are provided in each block & Storage areas and at strategic
locations for thorough washing in case of chemical splashes/hot burns / chemical burns.
MEDICAL EXAMINATION OF THE EMPLOYEES:

Medical examination of all employees will be carried out once in a year. All employees medical
Records have maintained in personnel departments.
AMBULANCE AVAILABILITY IN CASE OF EMERGENCY:
Ambulance van available with trained driver available at site round the clock for any kind of
Emergency. Ambulance having following safety items.
A wheeled stretcher with folding and adjusting devices, with the head of the stretcher capable of
being fitted upward.
Fixed suction unit with equipment.
Fixed oxygen supply with equipment.
Pillow with case - Sheets - Blankets; Towels.
Emesis bag; Bed pan; - Urinal - Glass
Flares with life of 30 minutes - Flood lights
Flash lights - Fire extinguisher dry powder type;
Insulated gauntlets.
portable suction unit, portable oxygen units
Bag-valve-mask, hand operated artificial units
Airways, Mouth gaga - Trachoestomy adaptors
Short spine board, I V Fluids with administration units

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B.P. Manometer, Cugg,- Stethoscope
Long and short boards, wire ladder splints
Triangular bandage, long and short spine boards
Gauge pads 4" x 4", Universal dressing 19" x 36"
Roll of Aluminium foils, soft roller bandages 6" x 5 yards adhesive tape in 3" roll, safety pins
Bandage sheets-burn sheets
Poisoning : Syrup of Ipecac, Activated charcoal pre-packed in doses, snake bite kit, drinking waterpre-packed in doses
Emergency medicines: As per requirement under the advice of medical officer.
COMMUNICATING THE EMERGENCY INSIDE THE FACTORY PREMISES:

Means of communications: Following are the means of communication
Public address system

Intercom System
Walky talky
Megaphone
Hand Operated Siren (in case of power failure) installed at main security gate
Electrical Siren (Emergency Siren 3 Km Range) installed at main security gate
Hooters inside the process plant / other buildings
Messengers/Runners
By continuous whistle: The Security will alert the persons soon after receiving the
information about the emergency.
For communicating the declaration of emergency and evacuation decision to the plant
personnel, the electrical siren is used by the security officer upon getting instructions from site
incident controller / Incident controller / Emergency coordinator / HOD (Safety & Health)
COMMUNICATION WITH LOCAL SERVICES:

In case of need from the nearby fire stations, Hospitals, help is sought by contacting on the following
number by Personnel and Administration Co-ordinator during working hours and by emergency coordinator beyond working hours
Fire Station, Shadnagar.

Fire Station, Mahaboobnagar
Govt. Hospital, Kothur
Tel.Ph.No.282101
Tel.Ph.No.252101
Tel.Ph.No.252361
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In consultation with Site Controller / Incident controller, the Manager- Administration communicates
The information to the following department, depending on the nature of the disaster/emergency:
Director of Factories, BRK Bhavan, Lower Tank Bund.

Dy.Chief Inspector of Factories, Mahaboobnagar
Inspector of Factories Mahaboobnagar
A.P.Pollution Control Board Sanath Nagar, Hyderabad.
Environmental Engineer Regional Office Mahaboob nagar
District Collector Mahaboob nagar District.
Superintendent of Police, -- Mahaboob nagar District.
Circle Inspector of Police, -- Kothur, Mahaboob nagar District.
Inspector of Police, -- Kothur, Mahaboob nagar District.
Mandal Revenue Officer, -- Kothur Mandal.
Gram Panchayat, -- Mekaguda village.
ESCAPE ROUTES - FOR EVACUATION:
Escape routes are those that allow reasonably safe passage of persons from the work area to the
Assembly Points.
The emergency exits boards/marking with the arrow directions are provided in all production
Blocks/rooms, QC buildings, Raw Material Stores. The Way to Assembly Point signage boards
Are provided at various strategic locations so as to reach the desired Assembly Point depending
Upon the wind direction
WIND SACKS:
During an emergency, the knowledge of exact wind direction helps the plant Personnel to decide
on the selection of right escape route for safe evacuation of Personnel and also the safe assembly
point.
The wind sacks are provided at the following locations and the locations of wind sacks are marked
in the site plan
S.No Block/Location
PB-I Building
PB-II Building
PB-V Building
PB-VII Building
SRP column
MPB-E& F
MPB-G
P&A Building
Stripper column
Depending on the wind direction, the escape route is chosen and personnel are given guidance for
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Escape through these routes. Refer site plan for escape route.
SAFETY SHOWERS AND BODY WASHERS:
[
Readily accessible means of drenching water for workers, parts of body of workers and, clothing of
workers who have been contaminated with hazardous and corrosive substance; and such means shall be
as per the scale shown in the Table below.
S.No
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.
16.
17.
18.
19.
20.
21.
22.
23.
24.
25.
26.
27.
28.
29.
30.
31.
32.
33.
34.
35.
36.
37.
Block/Location
PILOT PLANT
PB-I
PB-I
PB-II
PB-II
PB-III
PB-III
PB-III
PB-IV&VI
PB-VII
PB-V
PB-V
SRP
ETP
ETP
INCINERATOR
RO PLANT
DM PLANT
WH-I
WH-II
WH-II
SOLVENT YARD
WH-III
WH-IV
WH-IV
MPB-A
MPB-A
MPB-B
MPB-B
MPB-C
MPB-D
MPB-D
QC-LAB
MPB-E
MPB-E
MPB-E
MPB-F
E.S & B.S Numbers

SFT-ESBS-01
SFT-ESBS-02
SFT-ESBS-03
SFT-ESBS-04
SFT-ESBS-05
SFT-ESBS-06
SFT-ESBS-07
SFT-ESBS-08
SFT-ESBS-09
SFT-ESBS-10
SFT-ESBS-11
SFT-ESBS-12
SFT-ESBS-13
SFT-ESBS-14
SFT-ESBS-15
SFT-ESBS-16
SFT-ESBS-17
SFT-ESBS-18
SFT-ESBS-19
SFT-ESBS-20
SFT-ESBS-21
SFT-ESBS-22
SFT-ESBS-23
SFT-ESBS-24
SFT-ESBS-25
SFT-ESBS-26
SFT-ESBS-27
SFT-ESBS-28
SFT-ESBS-29
SFT-ESBS-30
SFT-ESBS-31
SFT-ESBS-32
SFT-ESBS-33
SFT-ESBS-34
SFT-ESBS-35
SFT-ESBS-36
SFT-ESBS-37
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38.
39.
40.
MPB-F
MPB-F
MPB-J
SFT-ESBS-38
SFT-ESBS-39
SFT-ESBS-40
IDENTIFIED EMERGENCIES AT SITE:
Fire and Explosion

Toxic gas release
Spillage of chemicals from storage and from process
Flooding
Earthquake
Lightning
Food poisoning
CATEGORIZATION OF EMERGENCIES:
The plant areas where major emergencies such as Fires or Explosions or Toxic Releases are
expected to take place are identified. The various emergencies are categorized as given below: Category I Emergency:
Minor Emergencies which may or may not cause damage or injuries within any production blocks/Raw
Material Stores/Section of the factory and which are not likely to develop to a magnitude that warrants
evacuation of the personnel from the plant/ section of the factory. Such emergencies can be controlled by
the Section In charges & plant personnel only.
Example:
Minor fire near reactor manhole
Minor fire near centrifuge area
Minor fire near drier area
Minor fire dry grass fire
Minor fire at empty container storage area
Minor fire in ETP area
Minor fire in workshop
Minor fire in contractor sheds
M Minor Fire in QC/QA block
Minor Fire in warehouse

Category II Emergency:
Emergencies, which may or may not cause damage or injuries within any Production Blocks/Plant/Raw
Material Stores/Section of the factory, are likely to develop or have developed to a magnitude that
warrants evacuation of personnel from the plant/section of the factory.
Category II Emergency can be controlled effectively using resources within the factory and requires
initiation of Onsite Emergency plan by the Site chief emergency Controller/ site Incident Controller
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Examples:
Day storage tanks for ML, Spent Solvent, and Fresh solvent
Fire in Raw Material Stores
Fire in Incinerator
Fire in Bulk Liquid Storage Area
Fire in Spent Solvent Storage Area
Fire in hazardous waste storage shed
Explosion in liquid nitrogen tank
Explosion in liquid oxygen tank

Category III Emergency:
Emergencies, which may cause material damage or injuries and likely to have an impact on entire
operation of the factory. Such emergencies may be controlled using resources within the factory and
resources available in the surrounding establishments, outside help and requires initiation of On site
Emergency plan by the chief emergency controller.
Examples:
Fire in Bulk Solvent Storage tanks in Tank Farm
Fire in Production blocks
Toxic gas release from bulk storage tanks in tank farm (Bromine /Chlorine gas leak).
Toxic gas release from Dry HCl cylinders storage shed and battery at production block
Fire in Hydrogen cylinders storage and reactor area in Block-IV
Release of ammonia from ammonia gas cylinders.

Category IV Emergency:
This type of major emergency is like to have an impact on the surrounding area. Resources from Local
and State Government may be required to control such an emergency.
Category IV Emergency requires initiation of On site Emergency Action by the Site Incident
Controller and Incident Controller and co-ordination with District Emergency Authority for Offsite
Emergency Action.
Examples:
Earthquake
Flooding
Food poisoning
Cyclone
Category V Emergency:
Major Emergencies that can occur outside the factory premises during transportation of flammable
Toxic Materials like Methanol, Toluene, Ethyl Acetate, etc., which are procured by NPCD fall
Under this Category.
Emergency situations may also arise during transportation of treated effluent to PETL (as and when
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Required), hazardous wastes & spent solvents from our sites to TSDF & authorized agencies as the
Case May be. Emergency arising due to transportation of finished goods & intermediates from our
Site to suppliers are Co-ordinate by Safety, Commercial, Marketing & Quality Assurance Team.
Assistance from suppliers, Transporters, police and fire services may be required to control such
Emergencies. The NPCD Management has also to co-ordinate with the District Emergency
Authority to initiate actions as per the Off site Emergency Plan prepared by the District
Emergency authority.
Examples:
Major Fire Emergency of Road tankers transporting flammable solvent/corrosive chemicals in bulk
toxic chemicals/gases in bulk.
Major spillage of treated effluent & hazardous wastes (solid & liquid)
Fire incidents of trucks/vehicles during transportation of hazardous wastes from our site to PETL
(for Effluent), TSDF (for Hazardous wastes) & authorized agencies (for hazardous by products,
spent solvents & wastes)
Emergency situations due to accident of vehicles/trucks carrying & transporting finished goods
& intermediates.
NOTICING Of FIRE/ EXPLOSION OR TOXIC RELEASE EMERGENCY:
Any person noticing an unusual occurrence or toxic release must break the manual call point which is
provided for all the buildings and blocks. He also communicates the emergency on Intercom No.335
which is available with second gate security gate
If any person notices fire he should start shouting "FIREFIRE-- FIRE". and break the manual call
point which is provided for all the buildings and blocks. Or raise the FIREBELL for a one minute.
He also communicates the emergency situation to security on Intercom No.335 which is available with
second gate security.
'HOOTER SOUND SHOULD. (Fire /toxic release any other emergency) first
inform the Section In charge or concerned Department Head immediately through intercom or
Walky talky.
Rush to the scene of Fire and help others in Fire fighting if he is trained in fire fighting
The Section In charge rushes to the incident spot and assess the situation. If the emergency is a
Major one falling under any of the categories other than category-1 will inform to the site
Controller through Intercom phone No 301 or through massager.
Incident controller immediately takes the charge of site and does all necessary actions with ERT
Team.
Incident controller give the information to Site Controller and Security department on Intercom
Phone no.335 or 333 or walky talky about place of Fire, material involved etc.
Arrange for the evacuation of the persons of the endangered block/area by using the emergency
Escape Routes to reach to the Assembly Point.
In absence of Site controller-Executive Vice President (CES), The Vice President (production) will
Take charge of site controller,
The Vice President-Production, is the Incident Controller, in case of absence of Incident
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Controller, Immediate subordinate at site will act as an Incident Controller during working hours
DECLARATION OF EMERGENCY:
During the General Shift from 8.45 AM. to 5.30 PM. the Site Controller has the authority to
Declare the emergency for all Categories.
During the working hours when the Site Controller/Incident Controller is not available at plant, the
Emergency Coordinator (Block In charges) has the responsibility and authority to declare a major
Emergency based on his assessment.
Production In charges of respective block is the Emergency Co-ordinator after the General shift
Hour from 6.00PM to 9.00AM and on Holidays.
On Sunday or on holidays the Emergency Coordinator (Block In charges) has the responsibility
And Authority to declare a major emergency based on his assessment.
Other than general shift, the duty officer who is available at site will be acts as a site controller
And Authority to declare a major emergency based on block in charges information. Information
Should be give to NDO on walky talky or intercom number 335.
The Night duty officer who is present on duty will take the charge of the ECC and do the
Announcement for evacuation of plant.
EMERGENCY IN NIGHT TIME:
The Night duty officer who is present on duty will take the charge of the ECC and do the
Announcement for evacuation of plant.
The NDO should contact all Emergency key personnel for providing the necessary resources in
Controlling an Emergency coordinator.
The NDO alerts Security Personnel to give Emergency Siren as per code, after assessing the
Gravity of the situation.
Block in charge will give instruction and guides his staff to tackle the situation, with the help of
Executive- Production & Executive Maintenance.
Block in charge will alerts Mechanical, Electrical, Security, Quality Assurance and other
Departments by lashing the news about the emergency and seeks their help.
Block in charge will alerts the Shift-in-charges of other blocks to be prepared for emergency action
i.e., to bring all the processes to safe position or to stop as the situation warrants and to take
Preventive measures to stop spread of Fire etc., and for orderly evacuation.
Block in charge will directs for the removal of other material from the vicinity of the incident.
Block in charge will arranges for evacuation of other staff, other than persons attending the
Emergency.
Block in charge will arranges for necessary Fire Extinguishers and Personal Protective appliances
For the persons with the help of emergency core team members for attending the emergency.
With the help of Occupational Health Centre, he arranges Medical Aid/First Aid to the injured.
He arranges for taking roll call at the assembly points to verify a find out any missing person and
Arranges to rescue the trapped persons if any.
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He communicates the information to the key persons i.e., Site Controller, Incident Controller,
DGM.-EHS, GM-P&A, Manager-Administration, through Security and after their arrival, he hands
Over the Charge to the Site controller / Incident Controller and helps them.
Major Emergency is declared by sounding the emergency siren as per the siren code to indicate the
Emergency.
Manual call point / Fire bell is operated for alerting the local area personnel for initiate the
Emergency.
CENTRALIZED ELECTRICAL SIREN:
This Electric siren gives an indication that an emergency exists in any part of the factory and this siren
gives wailing siren for Three minute pulsating tone (Long run siren with ON & OFF) & is raised by
the security officer upon receiving instructions from Site Controller/ Incident controller/DGM-EHS
who is Emergency Coordinator. The emergency siren code is given below.
For Fire /Toxic release Emergency

All clear Siren
- Wailing Siren for 3 Minutes ( Pulsating tone)

- Continuous long siren for 60 seconds
CONTROLLING THE EMERGENCY:
The sounding of an emergency siren is an indication to the personnel in the factory that an
emergency has arisen and if so directed, they have to shut down the plant to a safe position and move
towards the Assembly Point using the appropriate escape routes.
In case of Category IV & V emergencies, which are Off-site nature, the Site Controller has to
inform the District Emergency Authority (DEA) i.e. the District Collector of Mahaboob nagar
district.
The emergency operations are controlled from the emergency control center.
The emergency operations are controlled by the Site Controller with the coordination of incident
controller and DGM-EHS
There will be an emergency Siren for the entire Factory premises and same will be raised by the
security Officer/guard who sits in second gate after receiving the instruction from site incident
controller/ incident controller.
After raising the emergency siren, security guard shall open the Emergency control center for
occupying the site controller. And red flag shall be shown as emergency.
Site controller takes the charge of ECC and does the announcement through public address system
for total plant evacuation or partial evacuation of plant depending on the emergency.
Site controller also does the announcement for evacuation route and location assembly point etc.
FIRE PREVENTION / PROTECTION MEASURES:
All employees are trained in Fire Prevention and Basic Fire Fighting and also refresher courses are
Conducted at a regular interval.
A well-trained Security team is working round the clock in shifts to meet any emergency and rescue
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of Personnel trapped in any gas or fire accidents.

Smoking is prohibited in the plant area
All electrical installations are flame proof in fire hazard areas as per the Hazard Area classification.
Bonding & Earthing and bend or dip pipes (wherever) in solvent receiving lines are provided in the
Plant.
All Solvent Tank (Storage Tank, Receiving Tank) vents are provided with flame arrestors. All
Reactor vents are provided with flame arrestors.
Safety Valves / Rupture Discs are provided wherever applicable to prevent Explosion due to pressure
Medium velocity water spray system is provided for solvent storage tanks and day storage tanks for
Solvent and mother liquor tanks.
Automatic control of temperature and alarm are provided for critical reactions.
House Keeping is maintained and system is followed for removal of oil soaked cotton wastes and
Other combustible wastes to prevent spontaneous combustion.
Proper labelling system is adopted to prevent wrong addition of chemicals.
Proper storage methods are developed and incompatible chemicals are segregated and
stored
Separately to prevent fires.
PLANT LAYOUT AND FACILITIES:
The facilities of the plant are provided in a plot of 100 acres. It is having approach roads all around
the Plant.
Production area mainly consists of reactors, coolers, condensers, associated ancillary equipment,
fitters, pumps, driers, distillation set up, scrubbers etc.
Production block and dry shed have been allocated for the production of drugs and intermediate.
Warehouse will hold material received in barrels carbuoys, solid bags and in fiber drums.
Apart from the above storages, solvents are received and stored for operation in tanks and approval
from CCOE.
Boiler steam generation is based on furnace oil/coal for which a separate storage facility is
available.
Utility section consists of cooling towers and connected pumps, refrigerated salt-water circulation
system and one boiler for steam generation.
Since most of the reactions are carried out in the presence of Nitrogen to ensure inert atmosphere
and for purging equipment before commencing reaction a separate liquid Nitrogen Storage Tank is
provided with necessary safety precaution.
Production areas, storage yard, warehouse, peripheral area and utility yards have hydrants,
monitors, manual call points, landing hydrants and first aid firefighting equipment.
Fire protection system provided for all production block and storage area as per TAC norms.
Fire water storage is 600M3 an exclusive storage facility.
All supply lines are laid over ground; underground lines are with protective and anticorrosive
layers.
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Hydrant lines are pressurized with 7.0Kgs/cm2 pressure

All above ground day tanks have dyke and containment facility.
Flame proof electrical system in all process and storage areas where flammable material is
handled.
Shut down and trip systems.
All systems are built to specific standards.
Special precautions for truck unloading.
No Smoking within plant premises.
Regular testing of safety apparatus.
Fire drills to ensure preparedness.
Training for handling emergencies arising out of toxic gas release.
GENERAL INSTRUCTIONS FOR DURING AN EMERGENCY:
Speed is essential
Use the best presence of mind.
Raise the manual call point in case of fire/Explosion/toxic gas release etc.
Clarity of information and instructions to all concerned persons and authorities.

Ensure only trained persons are deployed for combating the situation and safety procedures are
followed.
In case of eventual evacuation, it should be in the opposite wind direction.
Telephone /walky-talky systems are to be used for essential communication to combat the
emergency.
In case of communication failure, send messengers by any means of transport available.

Adequate quantity of material to neutralize spills should be kept in ready supply. E.g. Soda Ash,
Sand etc.
Rush to the spot of fire and attempt to put out the fire with suitable things within his reach, if he is
trained in Fire Fighting, otherwise informs the concerned Section In charge and evacuate using the
Emergency Escape Route to Assembly Point.
Switch off electrical power, to the equipment on fire wherever possible.
Extinguish and Tackle the fire with suitable fire extinguishers available in the area.
If extinguishing fire is not possible, he should see that fire does not spread to nearby
materials/areas.
Use fire hydrant hose from the nearest Fire Hydrant Hose Boxes if trained in use of Fire Hydrant.
Operate the quick opening valve for the Medium Velocity Water spray system, if the fire is in on
solvent tanks, if trained in the operation.
Only Trucks and Tankers with flame trap, spark arrestors is allowed inside the plant.
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EMERGENCY COORDINATION TEAM:

Common Coordinators
Site Controller
Incident Controller
Safety & Evacuation
Coordinator
Medical Coordinator
Communication Coordinator
Fire Coordinator
Shut Down/Leak Control
Coordinator
Security Coordinator
Block wise coordinator
P.B I
P.B II
P.B III
P.B IV, VI & VII
P.B V
Kilo Lab and R&D
M.P.B A
M.P.B B
M.P.B C
MPB C Kilo Lab
P.P & M.P.B D
MPB- E block
Name & Phone Number

P.S.R.K. Prasad -301
Mobile :9866005215
T. Venkata Rao - 304
Mobile :9866005196
Prakash.B - 333, 345
8790560899
Dr. S.U.Nandur- 339
N. Satya Narayana -342
N. Venu- 334
K. Srihari- 313
Alternative
T. Venkata Rao- 304
Security Officer- 300 & 346

Name & Phone Number
J. Prabhakar Rao - 319
M. Prasada Rao- 315, 326
K.Srinivas - 370
R.C. Sekhar- 306, 327
R.C. Sekhar - 321
G.Vijay Kumar - 349 & 364
M. Prasada Rao -326
M. Prasada Rao -326
P.V. Prasad- 357
G.Vijay Kumar -330
Koteswararao -312
G. Vijay kumar -330
Security Supervisor
Alternative
K.S.C.Sekhar
P.Sudhakar
D Srinivas
Venkateswara Rao
Venkateswara Rao
Raghu Ram
K. Vinu Kondaiah
K. Vinu Kondaiah
Brahmaiah
Ch. Srinivasa Rao
Mr. Rama Krishna
Mr Venkateswara rao403 - 101
Mr. Nannapenai Srinivas392/393 -201,202
Mr. Krishna Prasad
Mr. G. Srinivas
S.M. Nazeer
K. Srihari- 313
Satyanarayana
M.C.V. Reddy
Rangarao- 381
MPB- F block
M. Prasada Rao -326
MPB- G block
MPB- J block
Warehouse I, II, III and IV
Maintenance
E.T.P and ATFD and MEE
Q.C Building
Administration Building
Mr. Ch Srinivas 384/394 - 31

M. Prasada Rao -326
M. Nageswara Rao -317 & 318
Ch. Brahma Rao - 355
P. Chiranjeevi Rao -354 & 324
Krishnarao Rao-305 & 309
N. Satya Narayana -342 & 338
M. Prasad Rao -326

K. Suresh/D. Prakash
G. Siva Prasad
M. Samba Siva Rao - 328
P. Koteswara Rao-367
S. Lakshmana Babu-350
RESPONSIBILTIES DURING EMERGENCIES:

i) Site controller: Executive Vice President CES,
Alternative: vice president Production
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Once receive the call from security or incident controller of any incident, he shall assess the
Situation quickly if possible and decide, if a major emergency is to be declared. If so, advice
Incident Controller /security (phone no. 335) to raise emergency siren accordingly.
On declaration of Major Emergency, ensure that outside help is called (Police, Fire Brigade, and
Ambulances) and if necessary NPCD is inform.
Ensure co-ordination between the Incident Controller and all the emergency team viz. Control
Team, Fire Fighting Team and Rescue Team First Aid and Medical Team, Stores, Transport,
Security, Engineering, Production etc.
In consultation with the incident controller direct the shutting down of the plant and evacuation of
the Personnel to safe locations, if required.
He declares emergency, directing other areas/blocks/section to stop processes
Ensure that any casualties are receiving attention, get additional help if required and ensure that
Relatives are informed.
Liaise with fire and police officers and advise them on effect outside the factory.
Ensure accounting of personnel.
Maintain continuous communication with Incident Controller and review the situation.
He is over all in charge of the emergency situation and spoke person for carrying out
Communication with Media / Press / Govt. Officials / NGOs, etc.
His task is to co-ordinate all the internal and external activities from the emergency control center
Located at Main Security Gate
Keep liaison with Government Officials viz. Factory Inspector, Director, Factories, Superintendent
of Police, Additional Fire Officer, and Pollution Control Board with assistance from Dy General
Manger EHS and Manager-Administration
Arrange for relief of personnel where emergency is prolonged with assistance from Manager(P&A)
If the toxic release extends to areas outside the factory premises and the emergency falls in the
Category IV, then inform the Police, Local Authorities like Gram Panchayat and the District
Emergency Authority specifically about such development and arrange evacuation, transportation
and Medical attention as required by the authorities.
Decide on termination of emergency, advice Incident Controller/security accordingly, and
Authorize the sounding of all clear siren.
Direct rehabilitation work on termination of emergency Ensure preservation of evidence.
ii) Incident Controller: Vice president Production

Alternative: Block Head
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Once receive the information from workmen / any other regarding incident, he shall rush to the
Spot and assess the situation quickly.
Communicate the emergency to the Site Controller immediately.
Give information to ECC security personnel (Phone 335) to raise emergency siren accordingly.
Incident Controller is the person directly responsible for controlling the disaster. He reports to Site
Incident Controller.
He handles the situation by arresting or containing the chemical release, or containment or
Suppression of Fire spread.
He advises Site Incident Controller about the magnitude of risk.
He arranges to segregate the material available in incident spot and arrange for its safe storage.
He brings the processes of the section to a safe position by stopping the process as situation warrants.
He ensures all his people are present at the assembly point and helps Security and Time Office in
Accounting the missing/trapped person, if any by taking roll call and recording.
He ensures that the injured persons are removed from the area of incident and brought to the safe
Place.
He guides the Core Team Members about type of reactions involved, the type of material in use
And in Stock around the hazard area, and controlling operations.
He Co-ordinates in arranging required personal protective appliances and ensures that fire
Extinguishers are available to the Fire Fighting team and Core Team Members tackling emergency
Situations.
He Co-ordinates with Safety & Security in incident control and in sending the injured for
Medical Aid.
iii) Block / Section Controller:
Communicate the emergency situation to the Incident Controller, safety

Suppress the emergency situation in the early stages
Directing the employees to designated Evacuation and Assembly points. Organizing the shut down
Operations of the process
Coordinating the shutdown of power and utilities to his section / block with the Shut down and leak
Control coordinator
Arresting any leakages and handling containment failures in his section / block with the Shut down
And leak control coordinator
Issuing further instructions to the employees as necessary
iv) Safety & Evacuation Coordinator:
Review and updating of EPRP

Collection and compilation of information on the emergency situation
Make provision of adequate additional control equipment if required
Directing rescue operations in the affected areas
Ensure that first aid to the injures is rendered properly
Decide and initiate necessary evacuation measures
Ensure that necessary preventive measures are initiated in the nearby area /plant/ industry /quarters
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Invalidate all safety permits issued in the affected and near-by areas
Arranging replacement of used or exhausted safety items
To report accidents and emergencies to Government authorities as per legal requirements
Ensures the necessary PPE is available for emergency team
v) Medical Coordinator:
To provide first aid treatment to injured persons

To arrange for hospitalization of injured persons if necessary
Mobilizing extra medical help from out side
Keep the information about the availability of medicines and facilities
vi) Communications Coordinator:
Maintaining a primary backup communications between the ECC and the blocks/sections
Communicate with external agencies like fire-brigades and hospitals
Alert neighboring areas
Arrangement of external medical treatment through factory medical officer
Sends messages to the key persons or to any plant persons, if required by a messenger
(Two vehicles are available at his command for this purpose.)
vii) Fire Coordinator:
Forms fire combat team in coordination with the incident controller

Fire containment and suppression operations
Rescue operations in the affected areas
Use of available portable fire extinguishers, sand along with the firefighting equipment to combat
the fire and to contain the spread of fire
Arranging the portable fire extinguishers from the unaffected area, if required
Arranging company vehicles as and when required
viii) Shut Down & Leak Control Coordinator:
Providing services of his staff to the incident controller for closing down the services
Isolate the power supply where ever required
Arrange to carry out assigned duties pertaining to salvage of all engineering services including
water supply, power supply, telephone systems and fire pump operations
Providing emergency repair / power services as necessary
Erecting barricades and other vehicle movement control devices as necessary
Providing for debris clearance and effected site clean up as necessary
ix) Security Coordinator:

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Controlling the movement of employees and vehicles at the site and maintaining the access lines
for emergency vehicles and personnel
Security Officer shall communicate with Site Emergency Team about the Incident.
Preventing unauthorized entry into hazardous or secured areas
Assisting with the Medicare and handling of injured persons
Assisting with fire combat team if necessary
x) Supervisor/ Officer of the affected area /Block: He will carry out the following jobs.
Under the leadership of Senior Supervisor the fire fighting team will work promptly to arrest the
fire with the aid of the Fire extinguishers available there if
Emergency is of category I use fire extinguishers and if emergency of category II & III using fire
Hydrant, water monitor, foam monitor, fire extinguisher DCP trolley for extinguish the fire.
All helpers, operators and other supervisors who are trained in fire fighting and operational safety
will assist him in fighting the fire.
On arrival of the shift in charge/Block In charge to the spot, all the personnel will work under his
instructions.
xi) Executive - Production/QA-QC /Maintenance / Stores Executive/Shift In charges / Managers:
Execute all the jobs to stop spreading of fire
Instruct for closure of all valves on pipe lines carrying inflammable material entering into the section
Remove combustible and flammable/explosive, toxic materials etc, if possible.

Advise on emergency stoppage of process, if needed.
Arrange for rescue of operations, if persons are trapped.
Call other agencies for help, material etc.
On arrival of Fire brigade, the fire will be put out under the directions of the
Executive-Safety / Production Executive / Shift In -charge.
xii) Shift Electrician/Supervisor: He will ensure the following jobs:
The shift electrician / supervisor must always available in his work area so that he can contact /
instructed to switch off power supply to be affected block / section.
In case of Fire / Toxic release the ventilation system of the affected section / block should be
Switched off
AHU should be restarted after ensuring the people have been evacuated
The person should be allow to enter into section / block by the section in-charge after ensuring the
toxic gas / obnoxious gas is absent
Remain alert on duty for any electrical isolation of equipment during the emergency.
Ensure that adequate power supply is available for sensitive plant operations.
Keep the generators in readiness, in case of power failure during emergency.
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xiii) Ambulance Driver:
The ambulance driver on duty shall rush to the Parking Area, take over the ambulance, and await
instructions from the Site controller or Factory Medical Officer or Male Nurse and then rushes to
the incident spot.
He should park the ambulance in such a way that it is not very near to the affected area.
Ambulance should be parked in the opposite wind direction in case of toxic release
He should park ambulance in reverse direction, so that the victim can be put in ambulance easily.
xiv) Manager Administration:
Regulate traffic movement within the factory

Arrange alternative transportation in case of breakdown of transport vehicles, ambulance etc.,
Arrange vehicles for transportation of injured persons
Arrange for relievers and catering facilities.
Inform kith and kin of casualties.
Arrange fund for emergency purchase of materials.
Take head count of contract workers
Alert neighbouring industries/villagers
In his absence, his immediate sub-ordinates take the charge for all the responsibilities.
xv) All Other employees:
On hearing the emergency siren, contact the section in charge for necessary action.
Do not leave your work area or go to the site of emergency and wait for the instructions for
evacuation.
If you are an employee of unaffected area, be ready to close down (shutdown) Operations / plant /
equipment in your work area.
Be ready to go to the nearby assembly point.
If you are present in an area, which is not your regular work place, inform the section in charge of
that area about your presence and follow his advice.
If you do not get any directions from the section in charge and if you happen to get affected at any
stage by the spreading toxic gas or fire, then act as indicated below:
In case you notice/smell leakage of toxic gas like chlorine then leave the place in cross wind
direction and precede the assembly point located in that direction.
Warn nearby employees, if possibly by shouting.
All hot work in progress within the factory limits must stop.
Affected Areas: The following factors should be checked off before normal operations may be
resumed. Permission from the authorities has been obtained.
Absence of explosive or toxic gases has been verified
The causes of the incident have been identified.
No new hazards have been created by the Incident.
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The search and recovery of missing persons is complete.

Damaged plant and structures have been made safe.
Access is safe and any temporary systems of work are safe and without risk.
POTENTIAL EMERGENCY SITUATIONS AT SITE:
S.NO
Location
Production
blocks
1. Spillage of flammable liquids, and spark due

to static electricity, mechanical friction,
electrical short circuit etc.
2. Sparks due to welding & cutting operations.
3. Mechanical friction sparks while centrifuging
leading to fire.
4. Fire due to static electricity while transferring
flammable chemicals.
5. Toxic gas release into atmosphere.
6. Confined space hazards.
Fire & explosion, air

pollution,
property
damage,
Resource
depletion,
injury
to
human beings.
Ware house
area.
&Bulk
storage
yard.
1. Spillage of flammable liquids, and spark due

to static electricity, mechanical friction,
electrical short circuit etc.
2. Spillage of hazardous chemicals while
handling.
3. Sparks due to welding & cutting operations.
4. Fire due to static electricity while transferring
flammable chemicals.
5. Toxic gas release into atmosphere.
6. Spark from running vehicles.
7. Accidental release of oxygen and nitrogen
1. Electrical sparks due to short circuit.
3. Fire & Explosion due to Welding & Cutting
of process equipment.
4. Spillage & Leakage of CaCl2 solution.
5. Explosion of boiler
6. Leakage of Flu gas from boiler exhaust
3. Fire & Explosion due to Welding & Cutting
4. Spillage & Leakage of HSD
Fire & explosion, air

pollution,
property
damage,
Resource
depletion, to human
beings. Liquid burns
2.
Services
Power
House
area.
Factors Leading to an emergency
Hazard
Fire
&
Explosion,
Property damage, injury
to human beings, Land
contamination
Burn and thermal heat
Fire
&
Explosion,
Property damage, injury
to human beings, Land
contamination.
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S.NO
Location
Factors Leading to an emergency
Q.C
Laboratory

2. Leakage of H2 gas.
3. Spillage of hazardous chemicals
handling in the lab.
Hazard
Fire & Explosion, air
pollution,
Property
while damage, injury to human
beings.
ENVIRONMENTAL EMERGENCIES:
S.NO
1
2
3
Location
Failure of water
pollution control
equipment
Dust collector at
boiler
Process scrubbers
Factors Leading to emergency

1. Overflow of water
2. Mechanical or electrical
breakdowns of ETP.
1. Failure of dust collector.
Failure of scrubber systems.
Hazard
Water pollution and
contamination
Land
Air pollution and

emission of dust.
Air pollution.
High
SPILLAGE OF HAZARDOUS CHEMICALS & WASTES:

S.NO
1
Location
Factors Leading to emergency
Production
area
block 1. Spillage during handling &

batch charging.
2. Failure of pipelines, valves &
storage tanks.
Ware house area
1. Spillage
during
Loading,
Unloading & transportation.
2. Failure of pipelines & storage
tanks.
Power house area
1. Spillage of HSD, LUB oil while
handling
Hazard
1.
2.
3.
4.
1.
2.
3.
4.
1.
2.
3.
4.
Air pollution
Water pollution
Land contamination
Resource depletion
Air pollution
Water pollution
Land contamination
Resource depletion
Air pollution
Water pollution
Land contamination
Resource depletion
EMERGENCY PROCEDURE FOR FIRE & EXPLOSION

After taking all the precautions regarding the identified hazards probability of emergency is
Reduced but it cannot be totally eliminated. To deal with such emergency, following procedure is
Adopted.
Any employee who notices a fire will shout FIRE-FIRE-FIRE to raise an alarm/to ring the
Fire bell at least 60 seconds. He will analyze the fire and immediately start the fire fighting
Operation with the use of fire extinguishers / buckets available in the department.
The person who hears him, he will then report the matter to his HOD/ In-charge.
HOD /In-charge of the department will immediately rush to the location of fire and inform
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regarding the type and nature of fire to Security, Safety department and to the plant manger
On the intercom phones, and for further action.
Shut-down & Leak Control Coordinator shall switch off the power supply to that area
Immediately to avoid further hazards.
The in-charge of that section informs the same to the Site controller.
Immediately after receiving the fire call, the fire combat will rush to the spot for fighting the fire
The Communications Coordinator asks the nearby fire station for further help in case of
Necessity.
Simultaneously while fighting the flammable, combustible materials, oxidants or explosives
Are removed to safer place wherever possible. If shifting of the above materials is not
Possible, the adjacent area also is sprayed with water as an additional precaution.
In case of any emission of toxic/ poisonous fumes while fighting the fire, the working
personnel shall use the mask with compressed air line / Self Contained Breathing Apparatus
(SCBA) set.
The Block / Section Coordinator shall bring all other process & activities to safe position or
Stopped.
The security department will instruct the guards to carry extra fire extinguishers and rush to
The location to take charges of the fire fighting operation.
If the fire is out of control, the safety officer arranges to start fire pump. Then he will rush
to the location and try to control the situation with the help of security guards, employees and
HOD.
The Safety officer and Factory Manger will assess the situation and call external agencies,
(Fire brigades), through phone calls for help if necessary. They will also inform all other
HODs concerned regarding the emergency.
In case of major fire, Security officer will give signal of alarm by operating the siren. When
the siren is given, evacuation of persons form the location of fire will be taken up as per
Instructions from the HOD. These persons shall assemble at locations identified as
Evacuation & Assembly points.
On the arrival of fire brigade, the in-charge of fire brigade will take charge of fire fighting
Operation and security officer with his team will assist him in the fire fighting operation.
The medical Coordinator will send ambulance and necessary stretchers to the scene and
Arrange for transportation and treatment of injured persons.
The Safety officer will give the information of the emergency to Government Authorities as
Per legal requirements. The Factory Manger will prepare written report of the incidence with
Help of Safety officer and send it to Government authorities and superiors.
FIRE AND EXPLOSION EMERGENCY IN SOLVENT TANK FARM AREA:
Solvent storage pool fire:
Methanol, Acetone, toluene, IPA Cyclohexene, and Hexane is a flammable liquid and having
flashpoint of less than 23 deg C. It is stored in horizontal tanks.
It takes approximately 2 hours for the leakage of 30 KL solvent from the tanks
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It takes approximately 14 hours for the vaporization of 1000 Kg of flammable solvent in a bund.
In the event of rupture of any solvent bulk storage tank, the entire quantity may spill into the dyke
area. If this dyke catches fire, the radiation effects will be higher than the tank fire.
The effect of radiation intensity levels from fires is given in Table No.1
The typical value and associated damage levels of thermal flux is given in Table No. 2
The consequence contour for Methanol Pool Fire is given in Drawing No.1
In case of pool fire, there will not be any harmful effect to the people up to a separation distance of
22 meter. The lower flammability limit distance for methanol vapour is 10 meter before it safely
disperses. If this vapour meets with an ignition source within the lower flammability limit distance
of 10 meter it will lead to a flash fire and pool fire as shown in the drawing No.1.
i) Solvent storage pool fire Damage caused at different incident levels of thermal radiation
S. No.
Incident
Flux KW/m2
1.
37.5
2.
25.0
3.
12.5
4.
4.0
Type of Damage caused

Damage to Equipment
Damage to people
Damage to process
100% lethality in 1 min
equipment
1% lethality in 10 seconds.
Minimum energy to ignited
wood at indefinitely long
exposure without a flame
Minimum energy to ignited
wood with a flame; melts
plastic tubing.
5.
1.6

Significant injury in 10 seconds
1st degree burns in 10 seconds
Cause pain if duration is longer than
20 seconds but blistering is unlikely
Causes no discomfort for long

exposure.
ii) Solvent storage pool fire - Typical value and their associated damage levels of thermal
Radiation
Relative Flux
KW/m2
1.0
6.0
12.0
24.0
Harmful Effects
Strong sunlight
Related to a Safe exposure assuming that shelter is found within one
minute.
Related to the flux required to weaken structural steel within tens of
minutes.
Related to the flux required to weaken heavy structural steel within tens of
minutes
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iii) Solvent storage pool fire: Results of Thermal Radiation

S.No.
Separation Distance (Meter)
Thermal Radiation KW/m2
28
4.0
18.0
37.5
12.5
12
1.
2.
3.
iv) Solvent storage pool fire: consequence contour for methanol storage pool fire:
DETAILED ACTION FOR HANDLING VARIOUS EMERGENCIES:

i) Action in tank farm area during Emergency:
The operator/technician after noticing fire/leakage in tank farm area informs 335/333 and
department in charges immediately.
Break the nearest manual call point immediately to alert the people.
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Take the nearest fire extinguisher to extinguish the fire if possible. Shout FIRE, FIRE / MANTA,
MANTA to alert the nearest person.
Emergency is declared by activating the siren, after noticing fire or explosion in tank farm area
Start using the fire hydrant points, water sprinkler, water monitor and foam gun kept near the tank
farm area.
Evacuate all the personnel in the tank farm area.
Stop all activities/loading unloading in the tank farm area
Cordon off the area and do not allow any person inside tank farm.
Inform Fire Station Shad Nagar/ Mahaboob Nagar about the Fire, if required.
Inform Chief Inspector of Factories and police station.
ii) Emergency procedure for Fire protection measures in solvent storage tank farm:
Following protective measures are provided for the solvent Storage Pool Fire Emergency.
Automatic deluge valve with MVWS (medium velocity water sprinkler) provided for all solvent
tanks.
Manual operated foam monitor system is installed over Solvent Storage Tank
Public address system available in tank farm area for communication
Portable Fire Extinguishers are kept in the solvent Storage Area.
The Fire Hydrant System surrounds the Solvent Storage Area.
Sand Buckets (12 Nos) are kept in the Solvent Storage Area.
Water monitors are installed at Solvent Storage tank farm area
300 Liters of foam Compound with a foam making branch is kept at solvent storage tank farm
All solvent tanks having condenser cooling with Flame arrestor provided.
Lightening arrestors provided to nearby area
Breather valves facility with Nitrogen blanketing provided to all flammable chemical storage tanks
MCP provided inside the solvent tank farm area
iii) EMERGENCY PROCEDURE FOR HANDLING FIRE AND EXPLOSION IN HYDROGEN

OR GAS LEAKAGE:
Hydrogen is highly flammable (2H2 + O2 2H2O). It can ignite in combination with as little as 23%
air (5% oxygen). Even small amounts of air in lines or storage tanks are potentially dangerous. In
addition, the friction caused by high-pressure gas passing through a narrow valve could theoretically
create enough heat to ignite hydrogen. Therefore, it is vital that no air be in lines. Before opening the
hydrogen gas valve, purge the line with nitrogen gas to eliminate air. On loss of containment, a harmful
concentration of hydrogen gas in the air will be reached very quickly. Hydrogen gas detectors have
been installed in the Storage and Reactor area.
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Effects of exposure to hydrogen:
Fire: Extremely flammable. Many reactions may cause fire or explosion due to Gas/air mixtures.
Inhalation: High concentrations of this gas can cause an oxygen-deficient environment. The symptoms
of exposure to hydrogen are headaches, ringing in ears, dizziness, drowsiness, unconsciousness, nausea,
vomiting and depression of all the senses. The skin of a victim may have a blue color. Pre-existing
respiratory conditions may be aggravated by overexposure to hydrogen. Ensure fresh air and rest to the
victim. Artificial respiration may be needed. Inform OHC.
Detection of Hydrogen flame: Hydrogen also burns with an invisible flame, which creates the risk of
discovering a fire by walking into it. Before entering the suspected hydrogen leakage/fire area, detect
hot spot using Infrared Gun. As an alternative, use a straw broom attached to 15 feet stick to find
suspected flames. Burning of broom indicates presence of hydrogen flame.
Fire: Shut off supply / depressurize the line / equipment. If not possible and no risk to surroundings.
Let the fire burn itself out. In other cases extinguish with water spray, powder, carbon dioxide or
Nitrogen gas. Keep cylinder cool by spraying with water. Combat fire from a sheltered position to
prevent explosion. Evacuate personnel from the area.
Use Aluminized fire suit while controlling fire
Use DCP based Fire Extinguishers for fighting the fire
Use Self Contained Breathing Apparatus while fighting hydrogen fire

iv) EMEGENCY PROCEDURE FOR HANDLING FIRE AND EXPLOSION IN REACTOR:
The operator/technician after noticing fire or explosion in reactor break the nearest manual call
point and informs 335/333 and department in charge
Emergency is declared by activating the siren, after noticing fire or explosion in Reactor.
Start using the fire hydrant points near the Production block.
Evacuate all the personnel in the production block. After announcement in the public address
system
Stop all activities in the production block
Stop all addition immediately in the production block
Inform Fire Station Shad Nagar/ Mahaboob Nagar about the Fire, if required.
Inform Chief Inspector of Factories & Boilers on Phone
v) EMEGENCY PROCEDURE FOR HANDLING FIRE AND EXPLOSION IN CENTRIFUGE:
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The operator/technician after noticing fire or explosion in centrifuge break the nearest manual
call point and informs 335/333 and department in charge
Emergency is declared by activating the siren, after noticing fire or explosion in Centrifuge.
Start using the fire hydrant points near the Production block.
Evacuate all the personnel in the production block. After announcement in the public address system
Stop all activities in the production block
Stop all additions immediately in the production block
vi) EMEGENCY PROCEDURE FOR HANDLING FIRE AND EXPLOSION IN BOILER:
The operator/technician after noticing fire or explosion in Boiler break the nearest manual call
Emergency is declared by activating the siren, after noticing fire or explosion in Boiler.
Start using the fire hydrant points near the boiler House.
Evacuate all the personnel near the boiler area to assembly area. After announcement in the
public address system
Inform Fire Station Shad Nagar/Mahaboob nagar about the Fire, if required.
vii) EMEGENCY PROCEDURE FOR HANDLING FIRE AND EXLOSION IN E.T.P:
The operator/technician after noticing fire or explosion in ETP break the nearest manual call
Emergency is declared by activating the siren, after noticing fire or explosion in ETP.
Start using the fire hydrant points near the boiler House.
Evacuate all the personnel near the ETP area to assembly area. After announcement in the
Inform to Fire Station Shad nagar/Mahaboob nagar about the Fire.
Inform Chief Inspector of Factories & PCB, Hyderabad.
Clean up the area with water.
viii) EMEGENCY PROCEDURE FOR HANDLING FIRE & EXPLOSION IN DIESEL

GENERATOR:
The operator/technician after noticing fire or explosion in DG break the nearest manual call
point and informs 335/333 and department in charge.
Emergency is declared by activating the siren, after noticing fire or explosion in DG.
Start using the fire hydrant points near the DG area.
Evacuate all the personnel near the DG area to assembly area. After announcement in the
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Cordon off the area and do not allow any person near D.G. House.
Inform Chief Inspector of Factories & Boilers on Phone
Inform Police Station
Clean up the area with water.
ix) EMEGENCY PROCEDURE FOR HANDLING LITHIUM ALUMINIUM HYDRIDE FIRE

Lithium aluminum hydride is a highly flammable solid. Reacts violently with water, acids, and many
oxygenated compounds; corrosive to skin, eyes, and mucous membranes. LAH reacts with many metal
halides to produce metal hydride products, which are flammable and toxic. Auto ignites in moist or
heated air. Lithium aluminum hydride is highly corrosive to the skin, eyes, and mucous membranes.
Contact with moisture forms lithium hydroxide, which can cause severe burns. Powdered LAH forms
dusts that can pose an inhalation hazard. Ingestion of this substance may cause aching muscles, nausea,
vomiting, dizziness, and unconsciousness and may be fatal. Ingestion can result in gas embolism due to
the formation of hydrogen. Exposure to water results in the release of hydrogen, which can be ignited
by the heat from the exothermic reaction. Lithium aluminum hydride should not be used as a drying
agent for solvents because fires can easily result (LAH decomposes at about 125 C, a temperature
easily reached at a flask's surface in a heating mantle). The decomposition products of LAH can be
quite explosive, and the products of its reaction with carbon dioxide have been reported to be explosive.
In case of Fire:
If anybody noticed, break the nearest manual call point.

Call 333 or walky talky to inform security gate.
Break the MCP of power shut down.( Blue colour)
Evacuate personnel from the area. Follow public address instructions
Use dry chemical powder or sand to extinguish fires involving lithium aluminum
hydride.
Never use water or carbon dioxide extinguishers on an LAH fire.
Use Self Contained Breathing Apparatus while fighting LAH fire.
Use Nomex Suit.
x) . EMEGENCY PROCEDURE FOR HANDLING SODIUM HYDRIDE FIRE
Sodium hydride (NaH) in the dry state is pyrophoric. The product is purchased as relatively safe
dispersion in Paraffin oil. Ignites spontaneously at room temperature in moist air. Reacts violently with
water, liberating highly flammable hydrogen gas; causes severe burns on eye or skin contact. Sodium
hydride reacts with the moisture on skin and other tissues to form highly corrosive sodium and
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potassium hydroxide. Contact of these hydrides with the skin, eyes, or mucous membranes causes
severe burns; thermal burns may also occur due to ignition of the liberated hydrogen gas.
In case of Fire:
If anybody noticed, break the nearest manual call point.

Evacuate personnel from the area. Follow public address instructions
Sodium hydride fires must be extinguished with a class D dry chemical extinguisher or
by the use of
sand, ground limestone, dry clay or graphite.
Water or CO2 extinguishers must never be used on sodium metal fires.
Use Self Contained Breathing Apparatus while fighting NaH fire.
Use Nomex Suit.
xi) . EMEGENCY PROCEDURE FOR HANDLING SODIUM METAL FIRE
Reacts violently with water, liberating highly flammable hydrogen gas; causes severe burns on eye or
skin contact. Sodium reacts with the moisture on skin and other tissues to form highly corrosive sodium
hydroxide. Contact of metallic sodium with the skin, eyes, or mucous membranes causes severe burns;
thermal burns may also occur due to ignition of the metal and liberated hydrogen.
Sodium spontaneously ignites when heated above 115 C in air that has even modest moisture content,
and any sodium vapor generated is even more flammable. Sodium reacts violently on contact with
water and often ignites or explodes the hydrogen formed.
In case of Fire:
If anybody noticed, break the nearest manual call point.( Red colour)
Evacuate personnel from the area. Follow public address instructions.
Sodium fires must be extinguished with a class D dry chemical extinguisher or by the use of
sand,
Ground limestone, dry clay or graphite.
Water or CO2 extinguishers must never be used on sodium fires.
Use Self Contained Breathing Apparatus while fighting sodium metal fire. Use Nomex Suit.
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xii) EMERGENCY PROCEDURE FOR HANDLING BROMINE LEAK:

While handling:
Use full PVC suit, Breathing apparatus, Rubber hand gloves, safety Shoes.
Use PVC apron, Rubber hand gloves, safety goggles and face shield (8 inch a Minimum.)
Highly corrosive. Do not allow contact with water.

In case of spillage:
Instruct other to be at a safe distance.

Neutralize the spills with Sodium thiosulphate solution and spread Soda ash liberally over
Spillage.
Collect neutralized material in double polyliner and keep in a HDPE carbouy and transfer to ETP
For further disposal.
Use SCBA and Full PVC suit while handling & controlling spillage.
Wash the spilled area with plenty of water after clean up is complete.
Keep adequate level of water in the dyke of bromine storage tanks in order to avoid vaporization of
Liquid bromine
Safety measures for bromine storage area: Bromine is handled in one of the stages of product and
Three liter bottles charging to reactors.
Bromine handling in bottles 0f one liter

Scrubber with caustic lye as neutralizing agent is provided.
One positive air suit and two numbers of fresh air line air masks provided.
Spill control kit and sodium Thiosulphate is provided.
PPE box containing PVC suit, PVC hand gloves, Face shields, Goggles, Cartridge masks etc
Provided.
Fire hydrant system is available. Tank form is surrounded by protective fencing.
Body and Eye shower provided.
xiii) EMERGENCY PROCEDURE FOR HANDLING CHLORINE LEAK:
If anybody smell or small leakage observed, inform to PB-V production block in charges
immediately.
If major leakage observed, break the nearest manual call point.
In case of leak Evacuate the people to safe area
Responders must wear SCBA and PVC suit, never direct water jet on liquid.
Use emergency kit for arresting leaks.
The emergency kit provided for chlorine leak from toner can also be used.
Always stand in up wind direction while attending to chlorine leak.
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a)
Use Ammonia torch for detecting the exact location of leak.

Follow the following procedure for arresting leak by using emergency chlorine kit
Chlorine leak through valve:
Bring the toner in top position by rolling the toner, set the triodes of the toner on the middle of the
toner, put rubber gasket over the leaking valve over rubber gasket, and tighten against the toner
valve by using stud with welded handle till the leaking stop.
b)
Chlorine leak through fusible plug:

Insert the yoke over hexagonal head of the fusible plug with stud passing through it. Place a blind
fiber gasket over the plug and tighten the stud so that leaking stop.
c)
Chlorine leak through threads:
Put the rubber gasket over leaking plug, inset the yoke with stud through it, put a small hood over
this arrangement, place a fiber gasket over the hood through the stud and fit the cap nut and tighten
till the leak stops.
d)
Chlorine leak from the body:
Position the leaking toner on rolling support in such a way that the leaking position is on the top.
Place around yoke plate with cap screw through it on leaking point. Attach one end of the chain to
the hook on the bottom side of the toner position the top cap screw on round yoke plate and tighten
till the leak stops.
e)
Chlorine gas leak from the pipeline:
Immediately stop the tonner valve. Wear SCBA /online mask and check with the ammonia torch. If
leaks detect correct the flush the line with nitrogen and correct the same. After the nitrogen pressure
test only reuse the line for chlorine passing.
Effects of exposure to chlorine at different concentrations on human beings:
Potential /Types of major hazards in Tonners:
Liquid Chlorine 10 nos. Of one-ton chlorine cylinders (tanners) are stored in the chlorine storage shed
Near the Production Block V. Following hazard is involving chlorine tonner leakage.
Rupture of 6mm copper tuning connection

Instantaneous failure of chlorine tanner releasing the entire quantity of 900 Kg. This probability is
very unlikely to happen.
Rupture of SS line after chlorine cylinder
Consequences of Chlorine release:
The rupture of 6mm copper tubing connection will cause spreading of toxic gas in the factory. The
worst case, and not likely to occur i.e. failure of 6mm connection and caustic scrubbing system not
coming on at the same time is considered. The details of areas likely to be affected and maximum
number of people likely to be present in each area.
Human effects from exposure to chlorine gas:
Exposure Level
Human Effects
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0.2 to 3.5 PPM

1.0 to 5.0 PPM
5.0 to 8.0 PPM
15.0 PPM
30.0 PPM
40.0 to 60.0 PPM
Threshold of odour perception in those individuals without chlorine exposure

to low doses of chlorine
Tolerated without undue ill effect for half to one hour
Sunlight irritation of the mucous membrane of the upper respiratory tract and
of the eyes
Effects are immediate. Irritation of nose, throat and eyes with cough and
lachrymator.
Immediate cough with a choking sensation, retrosternal chest pain and a sense
of construction in the chest. Wheezing due to development of branches
construction may occur. Possibility of nausea and vomiting.
Development of a chemical tracheo bronchitis and pulmonary oedema. The
later may develop after a latent period of several hours with marked
respiratory distress, restlessness.
Source: Chlorine Toxicity Monograph, Revised Edition 1989 institution of Chemical Engineers, UK
Safety measures for chlorine tonner storage area: Following safety measures available in chlorine
Shed.
Chlorine is received in 900 kg tonners.

Chlorine leak detection and alarm system and manual scrubber system provided with canopy
hood.
Scrubber consists of one tonne of caustic solution.
Two numbers of on line air masks provided in the chlorine cylinders storage area.
SCBA sets provided at storage area and control room.
Fire hydrant system provided to the area.
Eye shower provided at the area.
One set of emergency chlorine kit is provided inside the storage shed.
Manual call point available
Public address system for emergency communication
Wind sack available for identify the direction of wind.
xiv) EMERGENCY PROCEDURE FOR HANDLING DRY HCL LEAK:
Hydrogen Chloride is released in different reactions in the plant. The gas so released is drawn
through suction blowers and is neutralized through a scrubbing mechanism. The Maximum release
rate is assumed as 20 kg/hour, considering power failure, scrubber failure (for reasons of operational
failure or mechanical failures)
It is assumed that there could be a failure to draw so released Hydrogen Chloride gas for
various reasons like a mechanical failure of blower, power failure, no scrubbing medium in scrubber
tank etc. Out of all the processes considered in this analysis, IDLH: 50 ppm
Effects of HCL at various concentrations:
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S.No
1
2
3
4
Effects
Parts of HCl Vapour. Per Million Parts of

Air, by Volume
Barely Tolerable
Throat Irritation
Tolerable
Immediate Irritation
50-100 ppm per hour

35 ppm for short while
10 ppm
5 ppm
Dry hydrogen chloride is a toxic, colorless, liquefied compressed gas with sharp pungent odor.
Corrosive and irritating to the eyes, skin, and mucous membranes. Inhalation may result in
chemical pneumonitis, pulmonary edema.
Reacts with water or moisture in the air yielding dense, acrid HCL fumes. Reacts with fluorine,
calcium carbide, cesium carbide, rubidium carbide, and lithium silicide. Reacts vigorously with
alkalis and many organic materials with liberation of heat. Strong oxidizers cause release of
chlorine.
The operators engaged on handling of dry HCl gas cylinders must wear clean Gloves, ABM
and safety shoes.
While handling, cylinders must not be allowed to be dropped or permitted to strike against each
other.
Cylinders should be protected against direct sun (< 52C) when in use or under storage.
Transporting of dry HCL cylinders must be done by means of a cylinder trolley etc.,
Specially meant for cylinder transport. It is strictly prohibited to carry on shoulders or rolling
on the ground.
The safety devices provided on the cylinders must not be tampered with. Ensure availability of
Valve protective cap.
Welding on any cylinder is strictly prohibited.
Cylinders should not be used as rollers, supporters or any other purpose than to contain gas.
Never strike an arc on a gas cylinder. Never allow a cylinder to contact Electric lines or wires.
In case of HCL Gas leak:
If small leakage observed, inform to ware house in charges immediately.
Remove gas with fine water spray.
Stay in the upwind direction
Use emergency kit for arresting leaks. The emergency kit provided for chlorine leak from toner can
also be used.
xv) EMERGENCY PROCEDURE FOR HANDLING AMMONIA LEAK:
Ammonia is handled in cylinder in the plant. Assuming that one cylinder of Ammonia (50 kg). The
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Vapour concentrations over a period of one hour are computed for day and night conditions for IDLH
Level of exposure.
The following is result of such modeling: Day Condition
Wind: 1.5 meters/second from s at 3 meters
Ground Roughness: open country cloud Cover: 5 tenths
Air Temperature: 42 C
Stability Class: B
Direct Source: 50 kilograms
Source Height: 0
Release Duration: 1 minute
Red : 217 meters --(300 ppm = IDLH)
Night
condition:
Air Temperature: 12 C
Red: 736 meters ---
Stability Class: F
(300 ppm = IDLH)
Toxic effects
of ammonia release at different concentrations:
Concentration
General Effects
25 ppm
Odour detectable normally
100 ppm
No adverse effect on average
workers
400 ppm
Nose and Throat Irritation
700 ppm
1700 ppm
2400 ppm
5000 ppm
Immediate eye irritation

Coughing and severe eye
nose and throat irritation
Convulsive coughing
Respiratory spasms
Exposure Period
Maximum 8 hours
Deliberate exposure for long periods not
allowed
No serious effects after immediately 30 to 60
mts
No serious effects after 30 to 60 mts
Could be fatal after 30 mts
Fatal after 30 mts
Fatal within minutes
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10000ppm
Rapid asphyxia
Fatal within minutes
Ammonia is a Corrosive liquid and gas under pressure. Harmful if inhaled. Causes eye, skin, and
Respiratory tract burns. May cause kidney and respiratory system damage, Can catch fire. It is
Colorless liquefied compressed gas packaged under its own vapor pressure of 114 psig at 70 F.
Ammonia can cause severe eye, skin and respiratory tract burns. Overexposure may also cause
Central nervous system effects including unconsciousness and convulsions. Upper airway damage is
More likely to occur.
It poses an immediate fire and explosion hazard when concentration is in between 16% - 25 %,
Therefore, area must be ventilated.
Hand Gloves, ABM and safety shoes must be worn while handling of Ammonia gas cylinders.
Cylinders must not be allowed to be dropped or permitted to strike against each other.
Cylinders should be protected against direct sun (< 52C) when in use or under storage.
Transporting of Ammonia cylinders must be done by means of a cylinder trolley etc. specially
Meant for cylinder transport. It is strictly prohibited to carry on shoulders or rolling on the ground.
In case of NH3 gas leak:
If small leakage observed, inform to ware house in charges immediately.

Remove gas with fine water spray.
Stay in the upwind direction
Use emergency kit for arresting leaks. The emergency kit provided for chlorine leak from toner
can also be used.
In case of NH3 liquid leak:
In case of major leak Evacuate the people to safe area
Carefully throws polypropylene booms / pillows around and on the spill to prevent the spread
of
The spill.
Absorb the spill with polypropylene pads and squeeze the pads into disposable container.
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Pour dry sand on the spill and collect into disposable container. Neutralize the contaminated
area with about 5% Hydrochloric acid.
Flush the contaminated area with water to ETP till washings pH on pH paper is 6.0
7.5.
Send the disposable container containing Base liquid to effluent treatment plant,
disposable container containing Polypropylene pads, Booms to Incinerator and disposable
container containing contaminated sand to ETP Sludge drying beds for proper
detoxification.
xvi) EMERGENCY PROCEDURE FOR ACID /ALKALIES:
(THE SULPHURIC ACID, NITRIC ACID AND HYDROCHLORIC ACID AND SODIUM
HYDROXIDE):
Spillage may cause disaster due to spreading and contaminating with other incompatible
materials.Hence, the following measures are planned to control & contain such situations.
Adsorbents pads are used for small quantity spills.
The corrosive effect of these acids & bases either on metals or human tissues is due to their
affinity towards moisture. Hence to prevent corrosion with moist acid& base the vent lines are
provided with moisture free traps. At the time of emptying it is only dry air that fills the tanks.
In case of spillage of the acid & base plenty of dry sand is kept for dumping followed by de
harming with soda ash etc., wearing air mask, rubber gloves, full body PVC suit and gumboots.
Suitable bunds are provided around storage tanks to prevent the spreading and thereby isolating
and de harming.
Medical officer, First Aid, emergency team and fire departments are kept informed for rescue
operations.
The affected persons are removed to fresh air for instituting artificial respiration. Transfer the
injured persons if any, to Occupational Health Center for medical help.
In case spillage of the material, plenty of dry sand is kept for dumping around spills, followed
by wearing, rubber gloves, full PVC suit and gum boots etc.
Suitable bunds are provided around storage tanks to prevent the spreading and contaminating
the surrounding land.
People are evacuated and affected persons are removed to fresh air for giving artificial
respiration.
Dont use water to dilute the acid or flushing the spillage to drain
Wear full body suit/SCBA for handling emergency
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The corrosive effect of these acids either on metals or human tissues is due to their affinity
towards moisture. Hence to prevent corrosion with moist acid the vent lines are provided with conc.
Sulphuric acid traps. At the time of emptying it is only dry air that fills the tanks.
In case of spillage of the acid plenty of dry sand is kept for dumping followed by de harming
with soda ash etc., wearing air mask, rubber gloves, full apron and gumboots.
Suitable bunds are provided around storage tanks to prevent the spreading and thereby isolating
and de-harming
The affected persons are removed to fresh air for instituting artificial respiration
xvii) EMERGENCY PROCEDURE FOR HANDLING CHEMICAL SPILLAGES

Environmental Emergencies
Environmentally Potential Hazardous Areas: The following areas were identified as
Environmentally Potential hazardous/Emergency areas.
Solvent spillage in Tank Farm Area

Solvent spillage in Solvent Recovery plant
Spillage of liquid chemicals in Ware House Area
Spillage of chemicals/solvents in production blocks
Spillage of diesel in CVT room
Spillage of furnace oil boiler area
Chlorine Gas Cylinders Storage Area
Ammonia Gas Cylinders Storage Area
Dry HCl Gas Cylinders Storage Area
Hydrogen Gas Cylinders Storage Area
Mitigation of Environmental Emergencies:
If water is used for dosing fire, it may either enter the sewage and storm water drains, or goes to the
soil. Safety officer shall inform in-charge of ETP regarding the possible pollution of water in order to
arrange proper treatment and disposal by ETP.
If dry chemical powder or foam is used in fire fighting operation, it will be collected and disposed off
properly. If the water used to dose the fire, gets contaminated and goes to soil. Environmental experts
will assess the extent of land contamination and action will be taken as per their advice to reduce the
impact by proper storage, treatment and disposal.
Preventive Measures for chemical spillages at the time of Environmental Emergencies:
Small spillage: Any hazardous chemical spill that does not involve highly toxic, highly reactive, or
explosive chemicals in a situation that is not life threatening. This type of spill present a manageable
physical or health hazard to personnel who, when wearing proper Personal Protective Equipment (PPE),
will not be exposed to any chemical at a level that exceeds any level or permissible exposure limit.
Smaller Spillage Response & Cleanup Procedure:
If the spillage is of smaller quantity, cleanup the spilled material with suitable absorbent as per MSDS
and collecting suitable portable container and send it to Effluent Treatment Plant (ETP) where it should
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be treated / incinerated (Completed procedure incorporate in respective SOP Ref. No:

NPCD/SF/SOP/010).
Large spillages: Any hazardous chemical spill involves highly toxic, highly reactive, explosive or lifethreatening chemicals. (OR) Any spill situation that presents significant fire, explosion, or other
physical or health hazard risks, particularly if a person may be or has been significantly exposed,
contaminated or injured to such an extent that medical or other assistance is required. (OR) Any spill
situation that may adversely impact the external environment whether or not the spill occurred internal
or external to a building.
Note: If any chemical is present that, when spilled, could present a situation that meets this definition,
then emergency procedures for spill response, including cleanup, must be included as part of the work
places Standard Operating Procedure.
Large Spillage Response & Cleanup Procedure:
The area should be immediately evacuated particularly downwind area and Restrict access to the
area until completion of recovery and cleanup.
Eliminate all ignition sources and provide adequate ventilation depending upon the nature of the
chemical.
Stop or reduce leak if safe to do so.
Contain the material with earth sand or absorbent material which does not Reactive with spilled
material.
Recovery and cleanup should be done the trained personnel only. The person cleaning the spilled
material should wear required Personal Protective Equipment (PPE) such as respiratory cartridge
mask, safety goggles, gumboots, PVC Suit and rubber hand gloves etc
Do not touch the spilled material and avoid prolonged and repeat exposure to Toxic chemicals.
Prevent spilled material entering waterways, sewers or drainages.
Ground the containers if the spilled materials generate the static electricity.
Vacuum / sweep up the spilled material in an approved, portable and suitable containers as mentioned
the MSDS.
Place the containers with covers, labels and in suitable locations.
After recovering the material, cleanup the area with suitable absorbent Material as mentioned in
the MSDS.
Flush the area with water if it is required.
Disposal of Larger Spillages Materials:
After recovering the material, sent it to Effluent Treatment Plant (ETP).

Depending on the nature (physical & chemical properties) of material either the material is to be
neutralized or incinerated or it shall send for treatment and land filling.
xviii) EMERGENCY PROCEDURE FOR DISPOSAL OF CHEMICAL SPILLAGES OUTSIDE

THE BLOCK:
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The chemical spillage occurring in open ground not having secondary containment is first
retained at the spilled area by making a containment bund by using sand or murram (sand) around
spills.
If the spill is small. The spillage is then absorbed using absorbent pads and collected in a
double poly liner bags using PPE as per spill control procedure.
Sealed properly and sent to ETP department along with a waste transfer note for further
disposal.
If the spillage has entered into nearby storm water drains, then efforts must be made to retain in
storm water drains by putting sand bags.
If possible. If this cannot be achieved, then divert the spillages to fire water collection pit by
operating the valve towards firewater collection chamber.
This spill then will be pumped to drums/tanker for disposal to waste disposal site or to our
Incinerator.
xix) EMERGENCY PROCEDURE FOR HANDLING NITROGEN GAS LEAK IN CLOSED

ROOM
All close rooms are installed with oxygen sensors for monitoring oxygen. Normal oxygen will be
showing in sensor is 21 - 21.9% all the time.
In case of oxygen concentration reduced by less than 18.5% v/v due to nitrogen leakage, oxygen
sensor will activate and give buzzer sound.
Once hear the buzzer sound evacuate the place immediately.
Information should be given to block in charge for leakage of nitrogen
Block in charges will rush to the area and keep close the inlet of nitrogen line and open the door
and windows to increase the oxygen level.
After 20-30 minute, safety department will check the oxygen concentration in the area by portable
meter.
If oxygen is found more than 18.5%, then rectify the pipeline leakage and correct the same.
Check the leak test with pressure if found no leakage then hand over to production department
Again calibrate the oxygen analyzer then keep in ON.
Call immediately to 333/335 or
Contact immediately on walky talky
Evacuate the people from the affected area. If required
After 20-30 minute, safety department will check the Oxygen level concentration in the area by
portable meter
xx) EMERGENCY PROCEDURE FOR HANDLING LPG GAS LEAK IN CANTEEN AREA
LPG sensors installed for monitoring LPG in the canteen. Normal LPG level will be showing in
sensor is ZERO all the time.
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In case of LPG leakage and concentration reaches to 20% of LEL sensor will activate and give buzzer
sound.
Once hear the buzzer sound close the cylinder valve immediately.
Information should be given to canteen in charges for leakage of LPG
Canteen in charges will rush to the area and keep open the door and windows to dilute the LPG.
After 20-30 minute, safety department will check the LEL concentration in the area by portable meter.
If LEL is found ZERO then rectify the pipeline leak/cylinder leak and correct the same.
Check the leak test with pressure if found no leakage then hand over to canteen
Again calibrate the LEL sensor and keep in ON.
If observed the cylinder leakage disconnect the cylinder and bring cylinder to outer atmosphere
Break the nearest MCP, inform his supervisor about incident
Inform power house to switch off the main switch
xxi) EMERGENCY PROCEDURE FOR LPG GAS FIRE IN CANTEEN AREA
If anybody notice the fire in canteen, break the nearest manual call point immediately.
Extinguish the fire with portable fire extinguisher if possible immediately
Call immediately to 333/335
Inform to canteen in charges about fire
Evacuate the people from the canteen. If required
Start fire hydrant system to extinguish the fire if required.
After 20-30 minute, safety department will check the LEL concentration in the area by
Portable meter
xxii) EMERGENCY PROCEDURE FOR ELECTRICAL FIRE IN PANEL ROOM
If smoke detector activates immediately rectify the fire location

Break the nearest MCP , inform his supervisor about incident
Inform to service in charges about fire
Evacuate the people from the Panel area. If required
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Inform power house to shut off the main switch
xxiii) EMERGENCY PROCEDURE FOR ELECTRICAL FIRE IN MCC ROOM

Break the nearest MCP , inform his supervisor about incident
Inform to service in charges about fire
Evacuate the people from the MCC room. If required
Installed smoke detectors in cable trench area
xxiv) EMERGENCY PROCEDURE FOR HANDLING HT YARD FIRE

Inform to HT YARD in charges about fire
Evacuate the people from the HT YARD. If required
xxv) EMERGENCY PROCEDURE FOR HANDLING RANEY NICKEL FIRE

Inform to Block in charges about fire
Collect the spillage into disposable container containing water
Decompose the contents of disposable container by adding dilute Hydrochloric acid till the pH is
about 2 on pH paper and send to ETP
After 20-30 minute, safety department will check the LEL concentration in the area by portable
meter.
xxvi) EMERGENCY PROCEDURE IN SPILLGAE OF THIONYL CHLORIDE LEAK

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Break the nearest MCP, inform supervisor about incident

Pour dry sand on the spill and collect into disposable container
Neutralize the contaminated area with soda ash
Wash the contaminated area with water till washings pH become neutral
xxvii) EMERENCY PROCEDURE IN CASE OF SOLVENT FIRE

After 20-30 minute, safety department will check the LEL concentration in the area by portable
meter.
xxviii) EMERGENCY PROCEDURE IN CASE OF OXALYL CHLORIDE LEAK

Wear self-contained breathing apparatus and full protective clothing
Cover the spillage & Neutralize with soda ash and mix
Wipe the spill with polypropylene wiper and collect into disposable container
Send the disposable container containing contaminated solid to effluent treatment plant for proper
detoxification.
Wash the contaminated area with water
xxix) EMEGENCY PROCEDURE IN CASE OF Mg METAL FIRE

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After extinguishing fire collect the spill into a polyethylene bag and kept in disposable container
xxx) EMERGENCY PROCEDURE IN CASE OF TRIPHOSGENE LEAK
If phosgene leakage sensor will activate and give the local alarm
Break the MCP if necessary (multi inhalation), inform supervisor about incident
Inform to Block in charges about leakage
Inform to medical officer for HCl about inhalation.
Send affected personnel to hospital for treatment
xxxi) EMEGENCY PROCEDURE IN CASE OF TITANIUM TETRA CHLORIDE LEAK
If leakage use spill control kit

xxxii) EMEGENCY PROCEDURE IN SPILLAGE OF CAUSTIC SODA LYE
Inform supervisor about incident

Break the nearest MCP if required
Neutralize with acid and send to ETP
Wear PPE while handling the leakage
xxxiii) EMERGENCY PROCEDURE IN SPIILAGE OF ATFD HOT MATERAIL
Evacuate the person from the affected area. If required

Wash the Eye wash and Body wash at least 15 minutes
Inform his supervisor about the incident
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Inform to Block in charges about the incident

Send to first aid treatment for OHC department
xxxiv) EMERGENCY PROCEDURE FIRE IN HVD (HIGH VACCUM DISTILLATION)

Inform to Block in charges about incident
xxxv) EMERGENCY PROCEDURE IN CASE OF SCRUBBER FAILURE
Use standby scrubber if available

Stop charging / feeding activity if possible
Significant leakages of gases break the MCP.
Scrubber failure alarm system activates, inform to shift in charges
Evacuate the people by considering the wind direction if required
xxxvi) EMERGENCY PROCEDURE IN BOILER AND COAL STORAGE AREA
Extinguish the fire with portable fire extinguisher immediately if possible

xxxvii) EMERGENCY PROCEDURE FOR FIRE IN THERMIC FLUID HEATER
In case of fire CO2 flooding will activates automatically.

If CO2 system not activated , break the nearest MCP, inform to supervisor about incident
Still not activate the flooding system, manually release the cylinder knob for releasing the gas.
Call immediately to 333/335 or Contact immediately on walky talky
Inform to Block in charge about incident
Evacuate the people from the affected area.
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Inform power house to switch off the main power supply.
xxxviii) EMERGENCY PROCEDURE IN HAZARDOUS WASTE STORAGE
Break the nearest MCP, inform supervisors about incident

xxxix) EMEGENCY PROCEDURE IN HAZARDOUS TRANSPORTATION
Immediately park the vehicle, left side of the road.

Extinguish the fire with portable fire extinguisher immediately if possible
Barricade the area if possible
Call Fire Brigade. Immediately, phone no.101
Call Police station immediately , phone no, 100
Follow the TREM ( Transport Emergency) card, instructions
Communicate with Emergency contact numbers which is given in TREM card
Contain the leaked material by bund / secondary containment
Wear the PPE as per TREM card
xl) EMERGENCY PROCEDURE IN CASE OF FLOODING AND CYCLONE

As such there is the least possibility of flooding since the area is located in Deccan plateau and
moreover, the average rain fall is 60 cm. However, the following procedure is followed in case of
flooding:
Stop all operations immediately. Close all valves of solvent storage tank
Switch off power supply to avoid electrocution due to short circuit.
Evaluated information will be disseminated to personnel.
Shift the water reactive material to elevated places like racks / building as appropriate.
Activate the onsite warning and instructional system as necessary.
Follow unit shut down procedures and Shutdown Electrical power.
Control water flow by dike arrangement using sandbags, and or pumping.
Start up after checking and clearing water from each and every unit.
xli) EMERGENCY PROCEDURE IN CASE OF EARTHQUAKE
The factory premises is situated in Hyderabad which falls under Zone II under Seismic zone
classification and accordingly the probability and impact will be least to moderate.
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If stay indoors or inside the building follow:
DROP to the ground; take COVER by getting under a sturdy table or other piece of furniture; and
HOLD ON until the shaking stops. If there isnt a table or desk near you, cover your face and head with
your arms and crouch in an inside corner of the building.
Stay away from glass, windows, outside doors and walls, and anything that could fall, such
as lighting fixtures or furniture.
Stay inside until the shaking stops after that it is safe to go outside.
Do not attempt to move to a different location inside the building or try to leave.
Be aware that the electricity may go out or the sprinkler systems or fire alarms may turn on.
DO NOT use the elevators.
If stay out door or inside the building follow:
If staying outside the building move away from buildings, streetlights, utility wires. And stay there
Until the shaking stops.
If in a moving vehicle stay in the vehicle. Proceed cautiously once the earthquake has stopped
xlii) EMERGENCY PROCEDURE IN CASE OF LIGHTNING AND THUNDER

Lightning can strike any of the storage tanks as the storage yard is situated in open area and because of
vapors. This area is prone to attract lightning and also the same cause of elevated points. Even the spark
due to lightning can cause major fire. Hence the entire plant shall be protected with lightning arrestors
& conductors.
Lightning arrestors are provided on all the buildings and are connected to proper earthing. For the liquid
storage tanks in the solvent yard, huge lightning arrestors are provided with proper earthing. These
arrestors and earthing facilities are periodically checked. If any fire breaks out in-spite of this
arrangement, fire brigade personnel will fight out the fire.
In case of emergency the following procedures are adopted for first aid & other rescue operations.
The information is passed on to plant manager and he will immediately coordinate with all the
internal and external agencies for necessary action / help.
The Occupational Health Center / medical officer is informed to meet the emergency. The
ambulance is kept ready to take the injured persons.
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Nearby hospitals are informed explaining the nature of the accident for keeping necessary medical
facilities.
The fire department is informed for rescue operations
The concerned team will act according to the situation to avoid confusion and panic.
There is public address system in administrative building connecting all the areas, through which
all the concerned are alerted.
Nearest police station is informed explaining the nature of accident and precautions to be taken by
the people in the surrounding area.
The responsible officers inform the families of the injured persons and transport is provided for the
families of the injured persons.
xliii) EMERGENCY PROCEDURE IN CASE OF CYANIDE POISONING

Object:
XXXX Pharma Limited Chemical Division, Mekaguda Ware house and Production employees are
handling sodium cyanide & copper cyanide. Thus, there is a chance of exposing the employees to the
hazard of cyanide poisoning.
Diagnosis:
Cyanide is extremely toxic / poison without proper treatment cyanide poisoning may be rapidly fatal
exposure followed by collapse. A cross section of employees having similar symptoms headache /
nausea / difficulty in breathing / eye irritation / skin irritation / collapse / pink or cherry red or bluish
discoloration of skin immediately sent to the Occupational Health Center.
Communication:
Once the incident of cyanide poisoning is confirmed, the matter is reported to the doctor, senior officers
and the managers concerned, In addition transport will be arranged immediately so that medical
attention is immediately provided. While attending such cases the Medical officer / male and female
nurse will report the matter to the HOD / Exe. Vice President Corporate Engineering.
First aid:
The company is having a fully equipped (like Cyanide Anti-dote Kits) Occupational Health Center with
a qualified resident medical officer / male and female nurse in all the shifts, round the clock to deal with
cases, in giving first aid treatment, and then sending / referring to ESI/Govt. Hospital for further
treatment.
Instructions for the treatment of cyanide poisoning: Initial Therapy (in area of the accident)
Remove patient to no contaminated area.

Call doctor immediately.
If patient has stopped breathing; administer artificial respiration until normal respiration has
started. Administer artificial respiration again if necessary. This may be done with a respirator or a
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manual bag with pure O2. If neither is immediately available then the prone pressure method of
mouth-to-mouth resuscitation may be used.
Note: Maintaining an adequate airway is mandatory.
Have an assistant, break a Durule Amyl Nitrite Inhalant in a handkerchief and hold it in front of the
patients mouth for 15 seconds followed by a rest for 15 seconds. Then reapply.
Wash off any cyanide present on the skin. Remove any clothing that is contaminated by cyanide.
Keep the patient warm.
Specific Therapy (To be used at the discretion of doctor, nurse, or paramedic)
Initiate inhalation of O2 immediately while preparing for intravenous administration.

Simultaneously with the oxygen, administer Amyl Nitrite Inhalant for 15 to 30 second every 2 or 3
minutes.
Discontinue Amyl Nitrite and then inject 300 mg (10 ml of a 3% solution) of Sodium Nitrite
intravenously at the rate of 2.5 to 5 ml/minute. The recommended dosage of sodium nitrite for
children 6 to 8 ml/square meter (approximately 0.2 ml/kg of body weight) but should not exceed
10 ml.
Immediately thereafter, inject 12.5g (25 ml of a 50% solution) of sodium thio sulphate for adults.
The dosage for children is 7g/square meter of body surface area. But dosage should not exceed
12.5 g. The same needle and vein may be used.
If the poison was taken by mouth, gastric lavage should be performed as soon as possible. But this
should not delay the treatments outlined above. Lavage may be done concurrently by a third person.
A physician or a nurse, if one is available. One should take quick action without waiting for positive
diagnostic tests.
The patients should be watched closely for at least 24 to 48 hours. If signs of poisoning reappear,
injection of both sodium nitrite and sodium thiosulphate should be repeated, but each in one-half the
original dose even if the patient seems perfectly well. The medication may be given for prophylactic
purpose 2 hours after the first injections.
Warning:
Both sodium nitrite and amyl nitrite in excessive doses induce dangerous methemoglobinemia and
can cause death. The amounts found in a single Cyanide Antidote Package are not excessive for an
adult. The doses for children should be calculated on a surface area or on a weight basis, with the
dosage adjusted so that excessive methemoglobin is not formed.
If signs of excessive methemoglobinemia develop (i.e. blue skin and mucous membranes, vomiting,
shock and coma), 1% methylene blue solution should be given intravenously. A total dose of 1 to 2
mg/kg of body weight should be administrated over a period of 5 to 10 minutes and should be
repeated in an hour if necessary. In addition, oxygen inhalation and transfusion of whole fresh blood
should be considered.
Transportation:
The company is having one ambulance vehicle ready for use all the time. The patients after first aid
treatment are referred to the ESI / nearest hospital, and within 15 to 20 min the patient can be sent to
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the hospital. In addition to the ambulance, fleets of other vehicles like jeeps and pickup vans are
also available if the situation demands.
Statutory obligations:
Necessary information is sent to the following authorities as required by statute.
Local health authority.
Inspector of factories, Mahaboob Nagar Dist
The station house officer of nearest police station, Kothur and District Medical officer
Mahaboob Nagar Dist
xliv) EMERGENCY PROCEDURE IN CASE OF FOOD POISONING

Object: XXXX Pharma Limited Chemical Division, Mekaguda got a fairly large canteen with
facilities for mass cooking of breakfast / lunch / dinner & tea for the employees, working round the
clock in all shifts. Thus, there is a chance of exposing the employees to the hazard of food poisoning.
Diagnosis: A cross section of employees having similar symptoms sudden discomfort effecting the
digestive systems shortly after consuming canteen food are sent to the Occupational Health Center,
while attending such cases the Medical officer / male and female nurse will report the matter to the
HOD / Exe. Vice President Corporate Engineering.
Communication: Once the incident of food poisoning is confirmed, the matter is reported to the
doctor, senior officers and the managers concerned. In addition transport will be arranged immediately
so that medical attention is immediately provided.
First aid: The Company is having a fully equipped Occupational Health Center with a qualified
resident medical officer / male and female nurse in all the shifts, round the clock to deal with cases, in
giving first aid treatment, and then sending / referring to ESI/Govt. Hospital for further treatment.
Transportation: The Company is having one ambulance vehicle ready for use all the time. The
patients after first aid treatment are referred to the ESI / nearest hospital, and within 15 to 20 min the
patient can be sent to the hospital. In addition to the ambulance, fleets of other vehicles like jeeps and
pickup vans are also available if the situation demands.
Statutory obligations: Necessary information is sent to the following authorities as required by
statute.
Once the incidence of food poisoning is confirmed, the matter is communicating immediately
to the nearest Hospitals and Police Station.
Communicate Immediately to the Inspector of factories and Dy. Chief Inspector of Factories
Mahaboob nagar
Vehicles are kept ready for quick transportation.
Meanwhile First Aid is given to the affected persons.
The source of the poisoning may generally be canteen. Hence, the contaminated food is kept
Separately to avoid others getting affected.
Necessary information is sent to the following statutory authorities by the Incident Controller
As given below:
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Local health authority of Municipal Corporations

Police Station
END OF THE EMERGENCY: ALL CLEAR SIREN
After the emergency comes under control, Site controller (SC) along with fire and safety
coordinator will go around all the areas and confirm total control of the situation.
Communication coordinator will check for head count and tally employees and organize further
efforts through incident controller for search of missing persons.
After ensuring tally of head count and confirming control of emergency incident controller will
communicate end of emergency to site Controller who in turn assess the situation and inform
security to go on long-siren to declare End of Emergency.
At the sounding of All Clear Siren (three minute long siren)
Also site controller will do the announcement through the public address system for cease of the
Emergency.
Work in the unaffected areas of the factory shall resume.
EVACUATION PROCEDURE
For the purpose of this procedure, evacuation means withdrawal of personnel form places of work
in an Emergency.
All fires or dangers occurrences need not necessarily be followed by an evacuation.
If a fire or a dangerous occurrence is of a minor nature (i.e., very easily and quickly controllable),
Evacuation is not necessary.
If a fire or dangerous occurrence is likely to spread over a large area, goes out of control and is
likely to endanger the lives of the staff of the factory.
Evacuation of the employees of the entire factory is necessary.
The following procedures have been drawn mainly with a view to moving personnel form their
place of work to a safe place as quickly as possible and in an orderly manner, when a situation
arises where evacuation becomes necessary.
a) Sectional / Departmental Evacuation
When a fire or a dangerous occurrence (explosion, spread of fumes / vapors etc.) takes place, the
block in-charge or the section head or the production officer will immediately:
Make an on-the-spot assessment whether the situation warrants evacuation by the staff
Ensure that all operations have been brought to a satisfactory STANDSTILL STATE.
Order evacuation either orally or by blowing the whistle long blasts with short breaks in between.
Ensure that the visitors / contractors also evacuated.
Follow the public address system instructions.
b) Department head or the production manger or the production officer will immediately
Ensure that all operations have been brought to a satisfactory STANDSTILL STATE.
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Order evacuation either orally or by public address system

Ensure that the visitors / contractors also evacuated
c) Staff from all the department will:
Ensure an order has been given to evacuate, move quickly to the assembly point through the safe
exit in an orderly manner by the route.
Follow the instructions through public address system.
Ensure that no one exists in the section / department which is to be evacuated.
After the evacuation, take a roll call of the members of the concerned department in the assembly
points from the muster roll.
Report the missing names to the department head / security in charge / security guard.
d) General instruction to the staff:
Members of staff working in another department when an evacuation is announced will join the
staff of that department and proceed along with them to the evacuation assembly point of the
department where dangerous incident fire has occurred.
Staffs who are temporarily away from their place of workman evacuation has been ordered should
proceed to the evacuation assembly points and report about their safety to the department head or
their supervisor.
When staffs are away from their department, their department heads should be kept informed about
their whereabouts.
COMMUNICATION PROCEDURE DURING EMERGENCY:

Incident Spot:
The person, who noticed the emergency situation, should shout DANGER DANGER DANGER
and break the manual call point / fire bell at least 60 seconds and orally inform the people
surrounding him. Immediately the somebody should be communicating through phone
No 333/335 or walky talky about the type of emergency and location, over internal telephone or by
sending a person following persons.
Block In-charge
Incident controller
Security gate
Main Gate & Other Production Blocks:
One person in each block will be available near the department Internal telephone, to receive all
communications from Incident Controller. / follow the instructions through Public address system.
Security Officer shall communicate the Emergency to the following Persons:
Site Controller
Incident Controller
Emergency Coordinator
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Communication & Medical Co-Ordinator

All Production Blocks
The Communication Co-Ordinator through Site Controller will communicate with the required external
emergency services like fire brigade, hospitals and ambulance services etc. He will be in continuous
contact with incident spot, other production blocks, Assembly points and alert neighboring areas. Also he
will be responsible for updating the higher authorities.
Post-Emergency Procedure:
Review the incident; identify the remedial measures and implement. Disseminate the information within
the unit to prevent recurrence. Report to statutory authorities as applicable.
RECOVERY PROCESS PLAN
Introduction: Towards re-establishing normal operations at the earliest after an emergency the
following procedure will be followed. The section is divided into five parts:
1. Reconstruction of the accident scenario
2. Incident investigation
3. Establishing a recovery team
4. Damage assessment
5. Clean-up and Restoration
Post-Emergency and Recovery reporting after the major emergency has been cleared the scene needs
reconstruction with the help of persons who were associated with the scenario.
Incident investigation: To investigate the cause of the emergency and to prevent recurrence of the
incident requires thorough investigation. The investigation team should immediately seal off the
incident scene and commence its investigation to minimize the loss of any physical evidence.
The investigation of the scene should include photographing the area, identifying equipment from
fragments and note unusual items.
Written or recorded statements are to be taken from all operators involved, potential witnesses and
others who might have pertinent knowledge about the incident.
Report: A final report will be prepared giving details about the basic reason for the accident and will
work as a failure report covering equipment, maintenance, procedure, training, human error etc.
Recovery Team: In order to facilitate the restoration of normal operations of the company after an
emergency, a team is to be constituted by Chief Emergency Controller to manage recovery activities,
including damage assessment.
As a general rule, however, individuals representing Maintenance, Production, safety, Quality Control,
Accounts, Engineering etc., will be involved.
The recovery team is responsible for damage assessment, Clean-up and salvage operations and the
restoration of normal operations. A primary function of the recovery team will be to assess the damage
to structures, equipment and materials.
Clean-up and restoration operations:
As soon as incident investigations are completed and restoration plans have been made, clean-up and
restoration activities will commence.
Damaged equipment:
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Prior to restoration of normal operations, all affected equipments are to be tested and checked according
to procedures established.
Post-emergency recovery reports:
The officer-in-charge of Safety will hold review sessions with emergency response personnel to
evaluate: The adequacy of emergency response procedures.
1.
2.
The adequacy of the investigation for the cause of the incident.

Summarize the post-emergency activities.
Mitigation measures:
Following are safety measures and also the mitigation measures recommended to prevent any disastrous
situation listed under consequence scenario.
Fire fighting system (Fire extinguishers) is provided and the adequacy of the fire fighting system
may be assessed from consideration of minimizing the heat radiation effects due to jet fire, fireball
and flash fire.
Fire fighting system, Hydrant system, is introduced to mitigate the fire and exposure within a short
time.
Detectors are installed to detect and raise an alarm / alert.
Operating people should be educated on the results of Risk Analysis and prepare suitable action
plan to reduce the hazards under such situations.
All the personnel working inside the factory should be trained in various aspects of emergency
situations. Training program should be laid down for new employees and refresher training program
for the continuing employees.
Emergency Response Plan should be updated based on the risk analysis carried out for various
scenarios of the factory. Periodical drills to carry out to attack the situations cited.
Electrical continuity for the earthling of hydrocarbon tanks and pipelines should be ensured and
recorded at regular intervals to minimize static charge collection.
Personnel protective equipment should be placed and audited to make use during the emergency.
MUTUAL AID PROCEDURE IN MAJOR EMERGENCY SITUATION:

To define the criteria for requesting, or to provide a source to complement available resources within
and outside the neighborhood plants in major emergency situations.
The purpose of this procedure to define the criteria for requesting, or to provide a source to complement
available resources within and outside the neighborhood plants in major emergency situations.
This procedure can be applicable for XXXX PHARMA LIMTED Chemical Division, Mekaguda
and other mutual aid neighborhood plants names are mentioned below:
Indian Oil Corporation Limited, Kothur

Saint Gobain Vetrotex, Thimmapur
Anus Laboratory, Chilakammary
Actus Pharma Limited, Kothur
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Mutual Aid:
In the major emergency situation, recourses over and above those available at the works will be needs.
As the fire brigade reinforcement are relatively nowhere in our area, we may require additional sources
of extra supplies of firefighting equipment, breathing apparatus, manpower, ambulance and medical
Facilities. By our request at time of major emergency situation, the above-mentioned additional sources
of extra Supplies can be provided by the Mutual aid neighborhood plants.
Details about the Mutual Aid Industries with Phone Numbers:
S.No
Name of the
Company with
Location
XXXX PHARMA
1.
LIMITED
1.
Chemical Division,
Mekaguda
Distance
Away
from
XXXX
Contact Person
Designation
Contact Phone
No:
Executive
Vice President
CES
9866005215
--
Mr. P.S.R.K.
Prasad
--
Mr. Prakash .B
DGM- EHS
8790560899
10 Km
Mr. Sekhar
Kumar
Sr. Manger
Plant
9490958127
13 Km
Mr. Badi
Sr. Manger SHE
9848051530
5.
HBL KNIFE Power
4.
Systems Ltd
08 Km
Mr. S.P. Tripatti
Executive
Director
9394403020
6.
Anus Laboratory,
5.
Chilakammary
14 Km
Mr. E. Bhaskar
Rao
Plant Manger
9849201118
7.
Actus Pharma
6.
Limited, Kothur
9 Km
Mr. J. Jaya Rama

Reddy
Plant
Manager
9948320730
XXXX PHARMA
2.
LIMITED
2
Chemical Division,
Mekaguda
3. Indian Oil
2. Corporation Limited,
Kothur
4. OCV
3. Reinforcements,
Thimmapur
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INTERNAL TELEPHONE NUMBERS
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EXTERNAL AGENCIES TELEPHONE NUMBERS

S.NO
Name of External Agency
.
Fire Stations Phone Numbers:
Phone
1.
Fire Station Control Room
040 101
040 24600009
040 23260091
2.
Mahaboob Nagar Fire Station
08542 - 242299
3.
Secundrabad Fire Station
040 27842306
4.
Chandulal Biraderi Fire Station
040 24460722
5.
Malakpet Fire Station
040 24553230
Responsibility
Provision of fire tender

and rescue personnel

Hospital Phone Numbers:

6.
Divyas Hospital, Shad Nagar
08458-251821
7.
Siddhartha Hospital, Shad Nagar
08458-253687
8.
Apollo Hospital, Hyderabad
9.
NIMS, Hospital, Punjagutta
10.
Yasodha, Hospital, Somajiguda
11.
Gandhi Hospital,
12.
Osmania General Hospital,
13.
ESI Hospital, Sanath Nagar
Provision of ambulance
for transport of casualties
and medical treatment of
casualties
040 23607777
040 23320332
040 23318120
040 23319999
040 27713333
040 27702222
040 24600122
040 23701232
040 23701233
Police Stations Phone Numbers:

14.
Police Station, Kothur
08458-257233
15.
Police Station, Shadnagar
08458-252333
For necessary action if

required
For necessary action if
required
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Ambulance Phone Numbers:

16.
17.
Ambulance free service

St. John Ambulance
18. Apadbandhu Ambulance

Key Personal Contact Number:
S.No
040 102 & 108

040 24656785
040 27906948
040 24046733
040 24603566
NAME
For necessary action if required
Mobile Number
P.S.R.K. Prasad (Site Controller)
9866005215
Dr. D. Lingarao
9866005214
T. Venkatarao (Incident Controller)
9866005196
N. Satya Narayana
9949533374
B. Prakash
8790560899
CH. Brahma Rao
9849735219
P. Chiranjeevi Rao
9848196822
M. Nageswara Rao
9550240469
M. Prasada Rao
9490792732
10
K. Srinivas
9441803839
11
Dr Nandur
9985117079
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FIRE HYDRANT PUMP DETAILS: Fire hydrant water storage capacity: 600m3
1
Main Pump: Diesel

Make
:
Model
:
Rated Capacity
:
Total dynamic head at rated capacity :
Speed
:
Main Pump: Electrical
Make
:
Rated Capacity
Total dynamic head at rated capacity
Speed
:
Kilowatt
Kirloskar Brothers Ltd.,

DB 125/40
273 CU M/HR
70 MWC
1800 RPM

:
273 CU M/HR
:
70 MWC
1450 RPM
:
66.72
Pressurization Pump ( Jockey Pump)

Make
:
Model
:
DB 32/26
Rated Capacity
:
10.8 CU M/HR
Total dynamic head at rated capacity
:
70 MWC
Speed
:
2900 RPM
FIRE HYDRANT DETAILS: EMERGENCY EQUIPMENTS AVAILBLE AT SITE:

S.no
Equipment
Quantity
1.
Water tank capacity
600 KL
2.
Jockey Pump
10M3/h
3.
Sub Mersible pump
40M3/h
4.
Power Driven Pump (Main)
273m3/h
5.
Diesel Generator pump
284m3/h
6.
Single Hydrant
57 Nos
7.
Double Hydrant
5 Nos
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8.
9.
10.
11.
12.
13.
14.
15.
16.
17.
18.
19.
20.
21.
22.
23.
24.
25.
26.
27.
28.
29.
30.
31.
32.
33.
34.
35.
36.
37.
Water Monitor
Fire Escape Hydrant
Hose reel
Fire extinguisher
Fire extinguisher ( spare)
Deluge Valve with water sprinkler
CI alarm valve with water sprinkler
Foam monitor
Water monitor
Foam stock
Fire Suit
SCBA sets
5x Foam gun
Jet nozzles
Revolving nozzles
Water curtain nozzle
Jet and spray nozzle
Foam making nozzle
Foam solution
DCP Powder
SCBA sets
Chemical Cartridge masks
Normal fighting suits
Life jackets
Fall arrestor
Safety Net
Grip Ladder
PVC aprons
Nomax fire suit
Aluminized fire suit
5 Nos
7 Nos
37 Nos
412 Nos
20 Nos
11 Nos for 57 tanks
3 Nos
5Nos
5Nos
4200 Lts
4Nos
7Nos
20 Nos
57 Nos
1 No
2 No
10 No
20 Nos
4300 lts
600 kgs
6 Nos
66 Nos
6 Nos
4 Nos
10 Nos
12 Nos
6 Nos
15 Nos
03 nos
01 no
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LOCATION WISE PORTABLE FIRE EXTINGUISHERS:
DCP in Kgs
Location
R&D
QCD
QA
P&A
Canteen
Ambulance
Medicare
Security
gate
Quarters
Service-I
Service-II
N2 plant
DM plant
Compresso
r RM
Ice plant
Boiler
Power
House
Ware
house-I
Ware
house-II
WH-III
Ware
house-IV
Solvent
yard
ECC
Safety
Fabrication
yard
10
22.5
No of Fire Extinguishers
CO2 in Kgs
FOAM in Ltrs
150
2
1
2
1
2
4.5
1
3
50
150
Halatron
Kg
2
5
5
2
5
3
1
1
1
1
2
1
1
1
1
1
1
2
6
6
15
14
6
2
1
1
1
2
17
1
1
4
3
2
1
1
2
1
1
Total
2
17
5
2
5
1
1
1
1
2
1
2
8
3
6
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Kilo Lab
Pilot Plant
PB-I
PB-II
PB-III
PB-IV
PB-V
PB-VI
PB-VII
MPB-A
MPB-B
MPB-C
MPB-D
MPB-E
MPB-F
MPB-G
MPB-J
ETP
RO plant
SRP
Incinerator
MPB-CKL
MPBServices
5
5
2
1
1
1
5
3
4
5
7
7
4
1
1
5
5
1
1
2
1
2
1
4
5
7
1
1
2
2
16
16
2
1
1
2
1
2
2
1
1
1
2
2
2
5
8
6
2
1
1
1
3
1
1
3
2
3
1
1
1
1
5
2
1
1
2
1
17
27
22
10
4
6
9
10
13
20
11
7
3
6
27
27
6
6
34
33
21
5
4
2
6
5
18
5
412
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LIST OF ABBREVIATIONS
CES
ECC
EPRP
ERT
ETP
EVP
FLP
HOD
HSD
IDLH
KL
LEL
MPPB
Corporate Engineering Services

Emergency Control Center
Emergency Preparedness & Response Plan
Emergency Response Team
Effluent Treatment Plant
Executive Vice President
Flame Proof
Head of the Department
High Speed Diesel
Immediately Dangerous to Life and Health
Kilo Lab
Lower Explosive Limit
Multi Product Production Block
MSDS
PB
PEL
PP
PPE
PPM
PVC
SCBA
STEL
TLV
UEL
VP
MCP
PAS
DCP
Material Safety Data Sheet

Production Block
Permissible Exposure Limit
Pilot Plant
Personal Protective Equipment
Parts Per Million
Poly Vinyl Chloride
Self Contained Breathing Apparatus
Short Term Exposure Limit
Threshold Limit Value
Upper Explosive Limit
Vice President
Manual call point
Public address system
Dry chemical powder
Page 88 of 88
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Prepared by
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EPRP

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3.Tt The Concept

Objectives of the Emergency plan

Environment, Health & Safety (EHS) Policy

Brief Description of the plant

Key Personnel at the Factory

Minimum number of persons working in each shift

Hazardous Chemicals at site :

Solvent Tank Farm Area

Main Products Manufactured

Metrological Information: Predominant Wind direction

Emergency Power Supply

Emergency Control Center (ECC)

First Aid and Medical Facilities

Medical Examination of the Employees

Ambulance Availability in case of Emergency

Communicating the Emergency inside the Factory

Communication with Local Services

Escape routes - For Evacuation

Safety Showers and Body Washers

Identified Emergencies at Site

Noticing of Fire/ Explosion or Toxic Release Emergency

Emergency in Night Time

Centralized Electrical Siren

Controlling the Emergency

Fire Prevention / Protection Measures

Plant layout and facilities

General Instructions for During an Emergency

Organization Chart in Emergency

Emergency Coordination Team

Responsibilities During Emergencies :

ii) Incident Controller

Block / Section In charges

Safety & Evacuation Coordinator

Shut Down & Leak Control Coordinator

Supervisor/ Officer of the Affected Area /Block

Executive - All Departments

All Other Employees

Potential Emergency Situations at site

Spillage of Hazardous Chemicals & Wastes

Emergency Procedure for Fire & Explosion

Fire and Explosion Emergency in Solvent Tank Farm Area

Solvent Storage Pool Fire Damage Caused at Different Incident

Solvent storage pool fire: Results of Thermal Radiation

Solvent storage pool fire: Consequence contour for Methanol

Detailed Actions for Handling Various Emergencies

iii. Emergency procedure for Handling fire and Explosion in Hydrogen or

iv. Emergency Procedure for Handling fire and Explosion in Reactor

v. Emergency Procedure for Handling Fire and Explosion in Centrifuge

vi. Emergency Procedure for Handling Fire and Explosion in Boiler

vii.Emergency Procedure for Handling Fire and Explosion at ETP

viii.Emergency procedure for Handling Fire and Explosion in Diesel

ix. Emergency Procedure for Handling Lithium Aluminium Hydride Fire

x. Emergency Procedure for Handling Sodium Hydride Fire

xi. Emergency Procedure for Handling Sodium Metal Fire

xii.Emergency Procedure for Handling Bromine Leak

xiii.Emergency Procedure for Handling Chlorine Leak

xiv.Emergency Procedure for Handling Dry HCL Leak

xv.Emergency Procedure for Handling Ammonia Leak

xvi.Emergency Procedure for Handling Acid /Alkalies Leak

Emergency Procedure for Handling Chemical Spillages

Emergency Procedure for Disposal of Chemical Spillages Outside

xix.Emergency Procedure for Handling Nitrogen Gas leak in Closed Room